Industrial Sensors & Instrumentation worked example

Sensor Scrap Cost at 61% non-recoverable cost percentage: a worked example

Suppose non-recoverable cost percentage falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Calculate the total scrap cost from sensor production including scrapped components, failed assemblies, and rework that cannot be salvaged, so you can track waste trends and justify yield improvement projects.

The inputs for this scenario

  • Sensors scrapped per batch: 18 sensors (held at the documented default)
  • Average invested cost per scrapped sensor: 72 $ / sensor (held at the documented default)
  • Non-recoverable cost percentage: 61 % (the input this scenario stresses; the baseline uses 85)
  • Fixed scrap handling and disposal costs: 350 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable scrap cost = sensors scrapped x cost per scrap x (non-recoverable % / 100).
  • Total scrap cost works out to 1,141 $ at these inputs, and this is the headline figure for the scenario.
  • Scrap cost per sensor works out to 63.36 $ / piece at these inputs.
  • Variable scrap cost works out to 791 $ at these inputs.
  • Fixed scrap handling costs works out to 350 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where non-recoverable cost percentage sits at 85% and the headline result is 1,452 $, this scenario comes in 21.43% below the baseline at 1,141 $.
  • It computes total scrap cost and cost per scrapped sensor by combining the non-recoverable share of invested cost with fixed handling and disposal fees. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total scrap cost: 1,141 $ (headline result)
  • Scrap cost per sensor: 63.36 $ / piece
  • Variable scrap cost: 791 $
  • Fixed scrap handling costs: 350 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Sensor Scrap Cost calculator, set non-recoverable cost percentage to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.