Robotics & Automation worked example

Robot Scrap Savings at 1.44% scrap rate reduction captured by the robot: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop scrap rate reduction captured by the robot to 1.44%, then walk the calculation through step by step. Estimate annual dollar scrap savings from a robotic workcell using annual parts, scrap cost per part, scrap rate reduction captured, and any added quality cost.

The inputs for this scenario

  • Annual production volume: 500,000 parts / yr (held at the documented default)
  • Scrap cost per rejected part: 4 $ / part (held at the documented default)
  • Scrap rate reduction captured by the robot: 1.44 % (the input this scenario stresses; the baseline uses 2)
  • Added quality inspection and containment cost: 3,000 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Captured scrap savings = annual parts x scrap cost per part x captured scrap rate reduction.
  • Net annual scrap savings works out to 31,800 $ / yr at these inputs, and this is the headline figure for the scenario.
  • Scrap savings per part works out to 0.06 $ / piece at these inputs.
  • Captured scrap savings works out to 28,800 $ at these inputs.
  • Added quality and containment cost works out to 3,000 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where scrap rate reduction captured by the robot sits at 2% and the headline result is 43,000 $ / yr, this scenario comes in 26.05% below the baseline at 31,800 $ / yr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to scrap rate reduction captured by the robot, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It credits only scrap already eliminated; it assumes the captured reduction is sustained and does not model rework recovered short of full scrap or new failure modes the automation introduces.

Results at a glance

  • Net annual scrap savings: 31,800 $ / yr (headline result)
  • Scrap savings per part: 0.06 $ / piece
  • Captured scrap savings: 28,800 $
  • Added quality and containment cost: 3,000 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Robot Scrap Savings calculator, set scrap rate reduction captured by the robot to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.