Machine Vision & Industrial Inspection AI worked example

False Accept Cost at 1% defect escape rate: a worked example

This worked example runs the false accept cost numbers for a tougher week than the baseline: 1% defect escape rate instead of the typical 0.4%. Estimate the monthly cost of defects that escape inspection and reach the customer when a machine vision or automated inspection system incorrectly passes defective parts.

The inputs for this scenario

  • Monthly inspection volume: 50,000 parts / month (held at the documented default)
  • Average cost per escaped defect: 38 $ / defect (held at the documented default)
  • Defect escape rate (defective parts passing inspection): 1 % (the input this scenario stresses; the baseline uses 0.4)
  • Fixed monthly investigation and response cost: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Monthly defect escapes = monthly inspection volume x escape rate / 100.
  • Total monthly false accept cost works out to 20,200 $ at these inputs, and this is the headline figure for the scenario.
  • False accept cost per inspected part works out to 0.4 $ / piece at these inputs.
  • Variable escape cost works out to 19,000 $ at these inputs.
  • Fixed investigation and response cost works out to 1,200 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where defect escape rate sits at 0.4% and the headline result is 8,800 $, this scenario comes in 130% above the baseline at 20,200 $.
  • Use it during vision-system business cases, threshold tuning reviews, or after a customer escape to size the financial exposure of your current escape rate. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total monthly false accept cost: 20,200 $ (headline result)
  • False accept cost per inspected part: 0.4 $ / piece
  • Variable escape cost: 19,000 $
  • Fixed investigation and response cost: 1,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live False Accept Cost calculator, set defect escape rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.