Metals, Steel, Aluminum & Coil Processing worked example

Bar Stock Yield at 66% target bar stock yield: a worked example in metals, steel, aluminum & coil processing

Here is what the math looks like when conditions slip. We hold every other input steady and drop target bar stock yield to 66%, then walk the calculation through step by step. Estimate bar stock yield by dividing usable bar length by the purchased bar length, then see how far the yield sits from your target after cutoff and remnant loss.

The inputs for this scenario

  • Usable bar length after crop: 232 in (held at the documented default)
  • Purchased bar length: 250 in (held at the documented default)
  • Target bar stock yield: 66 % (the input this scenario stresses; the baseline uses 92)

Working through the calculation

  • The calculation starts from the formula this tool documents: Bar stock yield = usable bar length ÷ purchased bar length × 100.
  • Bar stock yield works out to 92.8 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target yield works out to -26.8 points at these inputs.
  • Usable bar length works out to 232 count at these inputs.
  • Purchased bar length works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target bar stock yield sits at 92% and the headline result is 92.8 %, this scenario lands almost exactly on the baseline at 92.8 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target bar stock yield, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats yield as a length ratio only; it does not account for kerf between parts or scrap from machining defects, which reduce usable parts further.

Results at a glance

  • Bar stock yield: 92.8 % (headline result)
  • Gap to target yield: -26.8 points
  • Usable bar length: 232 count
  • Purchased bar length: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Bar Stock Yield calculator, set target bar stock yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.