Packaging Automation & End-of-Line Systems worked example
Checkweigher Reject Cost at 92% share scrapped not reworked: a worked example
What does the result look like when share scrapped not reworked reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when checkweigher rejects are climbing and you need to size the dollar impact before chasing the root cause.
The inputs for this scenario
- Packs rejected: 100 packs (unchanged)
- Value per rejected pack: 45 $ / pack (unchanged)
- Share scrapped not reworked: 92 % (raised for this scenario; the documented default is 80)
- Fixed recheck and disposal cost: 250 $ (unchanged)
Working through the calculation
- Applying the documented formula (Variable reject cost = packs rejected × value per rejected pack × share scrapped not reworked) to the inputs above produces each figure below.
- At this operating point the engine returns 4,390 $ for total checkweigher reject cost, the number this scenario is built around.
- At this operating point the engine returns 43.9 $ / pack for reject cost per pack.
- At this operating point the engine returns 4,140 $ for variable reject cost.
- At this operating point the engine returns 250 $ for fixed recheck and disposal cost.
How this compares with the baseline
- Against the tool's baseline example, where share scrapped not reworked sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
- A figure at this level is achievable when share scrapped not reworked is genuinely sustained, not just peaked for a shift. It treats the scrap share as outright loss; if rejected product can be reclaimed, reblended, or sold as seconds, the true net cost is lower than shown.
Results at a glance
- Total checkweigher reject cost: 4,390 $ (headline result)
- Reject cost per pack: 43.9 $ / pack
- Variable reject cost: 4,140 $
- Fixed recheck and disposal cost: 250 $
Run it with your numbers
- Every input above is editable in the live Checkweigher Reject Cost calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.