OEE & Factory Performance worked example

Yield Loss Cost at 58% loss capture rate: a worked example in oee & factory performance

Suppose loss capture rate falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate cost of yield loss from lost units, margin per unit, and containment cost.

The inputs for this scenario

  • Scrap and rework units: 100 units (held at the documented default)
  • Cost per defective unit: 45 $ / unit (held at the documented default)
  • Loss capture rate: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed disposition cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Weighted cost = quantity × rate × capture factor + fixed adjustment.
  • Total yield loss cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Yield loss cost per unit works out to 28.6 $ / piece at these inputs.
  • Variable yield loss cost works out to 2,610 $ at these inputs.
  • Fixed yield loss cost adder works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where loss capture rate sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • It multiplies defective quantity by cost per unit and a capture factor, then adds a fixed disposition cost to return total and per-unit yield loss dollars. 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 yield loss cost: 2,860 $ (headline result)
  • Yield loss cost per unit: 28.6 $ / piece
  • Variable yield loss cost: 2,610 $
  • Fixed yield loss cost adder: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Yield Loss Cost calculator, set loss capture rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.