Lasers, Optics & Photonics Manufacturing worked example

Optics Scrap Cost at 98% scrap tracking capture rate: a worked example

This scenario runs the optics scrap cost calculation on the strong side: 98% scrap tracking capture rate, with every other input held at its documented default. Use this when quantifying scrap losses for a production lot, justifying investment in better polishing or coating equipment, or preparing a corrective action cost-benefit analysis.

The inputs for this scenario

  • Scrapped optical components this period: 18 pieces (unchanged)
  • Average value per scrapped component: 125 $ / piece (unchanged)
  • Scrap tracking capture rate: 98 % (raised for this scenario; the documented default is 85)
  • Fixed failure analysis and disposition cost: 300 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Tracked scrap cost = scrapped components x average value per component x capture rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,505 $ for total optics scrap cost, the number this scenario is built around.
  • At this operating point the engine returns 139 $ / piece for average scrap cost per component.
  • At this operating point the engine returns 2,205 $ for tracked scrap cost.
  • At this operating point the engine returns 300 $ for fixed failure analysis cost.

How this compares with the baseline

  • Against the tool's baseline example, where scrap tracking capture rate sits at 85% and the headline result is 2,213 $, this scenario comes in 13.22% above the baseline at 2,505 $.
  • Use it at period close or in a defect cost-of-quality review to size scrap losses on lenses, windows, mirrors or coated substrates and to build a business case for process improvement. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total optics scrap cost: 2,505 $ (headline result)
  • Average scrap cost per component: 139 $ / piece
  • Tracked scrap cost: 2,205 $
  • Fixed failure analysis cost: 300 $

Run it with your numbers

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

Last reviewed 2026-05-12.