Finishing calculator
Coating Defect Cost Calculator
Price the defects a coating run actually produced. Enter the rejected count, the share a recoat can recover, the second-pass cost and the loaded value of a scrapped part.
What this calculator does
- Price a defect batch through its rework-versus-scrap split, so failure modes rank by dollars instead of counts.
Formula used
- Rework cost = defective parts × recoatable share × rework cost per part
- Scrap cost = defective parts × (1 − recoatable share) × loaded value per part
- Total defect cost = rework cost + scrap cost
- Cost per defective part = total defect cost ÷ defective parts
Inputs explained
- Defective Coated Parts: Parts rejected for coating defects: orange peel, light film, contamination, runs.
- Recoatable Share: Defects a scuff-and-recoat recovers; the rest are valued as scrap.
- Rework Cost per Part: Full second pass: prep, repowder and the extra oven trip.
- Loaded Value per Scrapped Part: Loaded value at rejection: substrate, machining, pretreatment, powder, oven time.
How to use the result
- Best suited to ranking failure modes by dollars, not counts, showing why minority scrap defects own the budget, pricing the same defect rate across part families.
- A recoat that fails again doubles its cost and joins the scrap column. Containment labor, expedites and customer consequences sit on the scrap cost page. Defect attribution belongs to the review; this page prices the outcome.
Current U.S. benchmarks
- Industrial electricity averages 9.77 cents per kWh across the U.S. (EIA, Jul 2026), up 4.7% from a year earlier. Energy-intensive steps carry this directly into unit cost.
- The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% from a year earlier. Quotes priced off last quarter's material cost miss this move.
- The U.S. has 14,543 chemical manufacturing establishments employing about 911,245 workers (Census County Business Patterns, 2023).
Common questions
- Which coating defects can be recoated and which are scrap? Surface defects such as orange peel, light film and dry spray usually scuff and recoat. Contamination that blooms through a second coat, outgassing and substrate damage recur, so they belong in scrap.
- Why does scrap dominate the cost when most defects recoat? A scrapped part takes its whole loaded value while a recoat takes only the second-pass cost. At the defaults, 30 of 100 defects carry $360 of the $535 bill.
- What is a scrapped coated part worth? Its loaded cost at rejection: substrate, machining, pretreatment, powder, oven time and handling. Pricing it at the blank price understates the loss by everything the chain added.
- Where do inspection labor and expedites belong? Inspection and sorting are the quality operation's standing cost. Expedites and customer burden belong on the scrap cost page, so this figure stays comparable batch to batch.
Related guides
Last reviewed 2026-10-01.