Fitness Equipment & Connected Exercise Hardware worked example

Cosmetic Scrap at 3.45% target cosmetic scrap rate: a worked example in fitness equipment & connected exercise hardware

Push target cosmetic scrap rate up to 3.45% and the picture changes. This example computes every intermediate figure at that operating point. Use it when tracking scratches, paint defects, weld spatter, display blemishes, decal issues, packaging scuffs, frame dents, or visible fit-and-finish defects.

The inputs for this scenario

  • Cosmetic rejects: 8 units (unchanged)
  • Fitness units inspected for cosmetics: 250 units (unchanged)
  • Target cosmetic scrap rate: 3.45 % (raised for this scenario; the documented default is 3)

Working through the calculation

  • Applying the documented formula (Cosmetic Scrap rate = cosmetic rejects ÷ fitness units inspected for cosmetics × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 % for cosmetic scrap rate, the number this scenario is built around.
  • At this operating point the engine returns 0.25 points for cosmetic scrap gap to target.
  • At this operating point the engine returns 8 units for cosmetic rejects.
  • At this operating point the engine returns 250 units for fitness units inspected for cosmetics.

How this compares with the baseline

  • Against the tool's baseline example, where target cosmetic scrap rate sits at 3% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • It computes the percentage of inspected units rejected for cosmetic defects and the gap, in points, to your target rate. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Cosmetic Scrap rate: 3.2 % (headline result)
  • Cosmetic Scrap gap to target: 0.25 points
  • Cosmetic rejects: 8 units
  • Fitness units inspected for cosmetics: 250 units

Run it with your numbers

  • Every input above is editable in the live Cosmetic Scrap calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.