Renewable Energy, Solar & Wind Manufacturing worked example

Cell Breakage Cost at 1.3% wafer and cell breakage rate: a worked example

This worked example runs the cell breakage cost numbers for a tougher week than the baseline: 1.3% wafer and cell breakage rate instead of the typical 1.8%. Estimates the scrap and disruption cost of solar cell breakage during stringing and lamination.

The inputs for this scenario

  • Cells processed per run: 120,000 cells (held at the documented default)
  • Loaded cost per finished cell: 0.62 $/cell (held at the documented default)
  • Wafer/cell breakage rate: 1.3 % (the input this scenario stresses; the baseline uses 1.8)
  • Line stoppage charge per event: 800 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total loss = cells processed x cost/cell x breakage rate% + stoppage charge.
  • Total cell breakage cost works out to 1,767 $ at these inputs, and this is the headline figure for the scenario.
  • Cell breakage cost per unit works out to 0.01 $ / piece at these inputs.
  • Variable cell breakage cost works out to 967 $ at these inputs.
  • Fixed cell breakage cost adder works out to 800 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where wafer and cell breakage rate sits at 1.8% and the headline result is 2,139 $, this scenario comes in 17.39% below the baseline at 1,767 $.
  • Use it when reviewing scrap reports, evaluating a handling or stringer upgrade, or building a per-watt cost model for a cell or module line. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total cell breakage cost: 1,767 $ (headline result)
  • Cell breakage cost per unit: 0.01 $ / piece
  • Variable cell breakage cost: 967 $
  • Fixed cell breakage cost adder: 800 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Cell Breakage Cost calculator, set wafer and cell breakage rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.