Scrap Rate & Yield Calculator
Calculate manufacturing scrap rate, non-scrap yield and rework incidence from input, scrapped and reworked unit counts.
Calculate scrap rate and yield
Separate permanently scrapped units from units that require rework so quality loss is easier to interpret.
Scrap rate formula
Scrap rate = scrapped units ÷ total processed/input units × 100. The simple non-scrap yield shown here is the complement: units not scrapped divided by input. Keep physical-count boundaries consistent so components, pieces and finished units are not mixed.
Rework is not the same as scrap
Scrap represents output that is not recovered into conforming product under the measurement definition. Rework can consume capacity and cost while eventually preserving the unit, so this calculator reports rework incidence separately.
Yield versus First Pass Yield
A 98% non-scrap yield can hide extensive rework. First Pass Yield counts only units that meet requirements the first time. Use both when you need to separate permanent material loss from the hidden factory of repair and retest.
Measure cost as well as unit count
Unit-based scrap percentages can understate financial impact when high-value products fail disproportionately. Pair scrap units with material/labor value, defect cause, process step and disposition. Weight-based or cost-based scrap may be more useful for some continuous or mixed-value operations.
Normalize scrap to the decision you are making
Unit scrap is intuitive for discrete production, but weight, material cost or conversion value may be better for processes where units differ greatly in size or value. Keep numerator and denominator on the same basis and prevent reused/regrind material from being counted inconsistently. A good scrap dashboard often shows both physical loss and financial loss so teams can distinguish frequent low-cost defects from rarer high-cost failures.