Weighing, Dosing & Loss-in-Weight Feeding worked example

Quality Loss Cost at 58% cost-capture factor: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop cost-capture factor to 58%, then walk the calculation through step by step. Quality Loss Cost puts a dollar figure on out-of-tolerance doses from a weighing or loss-in-weight feeding operation, combining the variable cost of each bad unit — scaled by how much of that cost you actually recover or absorb — with a fixed charge for investigation, rework, and disposition.

The inputs for this scenario

  • Off-spec doses produced: 100 units (held at the documented default)
  • Cost per off-spec dose: 45 $ / unit (held at the documented default)
  • Cost-capture factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed investigation and rework cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Quality Loss Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where cost-capture factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to cost-capture factor, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The capture factor is a single blended percentage; it won't distinguish material cost you fully lose from labor you only partly absorb, so refine it per cost category for high-stakes decisions.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Quality Loss Cost calculator, set cost-capture factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.