Finishing worked example
Coating Scrap Cost with scrapped coated parts of 250 parts: a worked example
What does the result look like when scrapped coated parts reaches 250 parts? The full calculation is worked below with real intermediate numbers. Use this calculator for practical powder coating or surface finishing planning, quoting, troubleshooting, or line setup.
The inputs for this scenario
- Scrapped coated parts: 250 parts (raised for this scenario; the documented default is 100)
- Part value at scrap: 2.5 $ / part (unchanged)
- Sorting and documentation labor: 150 $ (unchanged)
- Replacement or expedite burden: 75 $ (unchanged)
Working through the calculation
- Applying the documented formula (Total cost = quantity × unit cost + labor/downtime + overhead) to the inputs above produces each figure below.
- At this operating point the engine returns 850 $ for total cost, the number this scenario is built around.
- At this operating point the engine returns 3.4 $ / piece for cost per piece.
- At this operating point the engine returns 625 $ for variable cost.
- At this operating point the engine returns 225 $ for fixed adders.
How this compares with the baseline
- Against the tool's baseline example, where scrapped coated parts sits at 100 parts and the headline result is 475 $, this scenario comes in 78.95% above the baseline at 850 $.
- A figure at this level is achievable when scrapped coated parts is genuinely sustained, not just peaked for a shift. It values parts at a single per-part figure; if scrapped parts span different stages of value-add, run it per group rather than averaging.
Results at a glance
- Total cost: 850 $ (headline result)
- Cost per piece: 3.4 $ / piece
- Variable cost: 625 $
- Fixed adders: 225 $
Run it with your numbers
- Every input above is editable in the live Coating Scrap Cost calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.