Tooling, Fixtures, Dies & Mold Economics calculator

Tooling Failure Risk Exposure Calculator

Estimate monetary exposure for one defined tooling failure scenario. Enter a supported period probability, the loss if it occurs and your expected loss review limit.

What this calculator does

  • Calculate expected monetary exposure for a defined tooling failure and compare it with your approved review limit.

Formula used

  • Expected loss = failure probability ÷ 100 × loss if failure occurs
  • Review headroom = expected loss review limit − expected loss

Inputs explained

  • Failure Probability for the Period: Supported probability of the defined failure occurring within your planning period.
  • Loss If the Failure Occurs: Total repair, downtime and recovery loss for that defined event.
  • Expected Loss Review Limit: Your approved expected loss limit for this event and planning period.

How to use the result

  • Best suited to tooling risk register Review, failure mitigation screening.
  • This does not estimate failure probability or replace safety and quality risk assessment. Multiple failures, correlated events and uncertain loss sizes need a fuller risk model.

Current U.S. benchmarks

  • The producer price index for plastic resins and materials stands at 280.569 (BLS, Aug 2026), up 6.6% from a year earlier. Quotes priced off last quarter's material cost miss this move.
  • The U.S. has 14,378 furniture and related products establishments employing about 355,594 workers (Census County Business Patterns, 2023).

Common questions

  • Can I enter a failure occurrence score? No. Enter a supported probability as a percentage for the stated period. A one to ten occurrence rating is not automatically a probability.
  • Does $3,000 expected loss mean the repair costs $3,000? No. Expected loss averages the entered failure loss with the zero-loss outcome. The actual event can cost the full consequence amount.
  • What should the failure loss include? Include the costs attributable to the defined event, such as repair, lost production and recovery. Avoid counting the same downtime or recovery cost twice.
  • Is a low expected loss a safety approval? No. Assess safety, quality and severe consequences separately. This calculation only compares monetary expected loss with your entered review limit.

Last reviewed 2026-10-06.