Mass Finishing, Deburring & Polishing worked example

Deburr Cost Per Batch at 58% batch utilization: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop batch utilization to 58%, then walk the calculation through step by step. Calculate deburr cost per batch for mass finishing, deburring & polishing planning, quoting, troubleshooting, capacity review, or process improvement.

The inputs for this scenario

  • Parts deburred per batch: 100 units (held at the documented default)
  • Deburr cost per part: 45 $ / unit (held at the documented default)
  • Batch utilization (bowl fill ratio): 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed setup and media cost per batch: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Deburr Cost Per Batch cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where batch utilization sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to batch utilization, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats the fill ratio as a flat multiplier on variable cost and does not model cycle-time changes, media wear curves, or parts that need a second pass for burr-free edges.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Deburr Cost Per Batch calculator, set batch utilization to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.