Scrap Rate Calculator
Calculate scrap rate, first pass yield, DPMO, sigma level, and the true cost of defects. See how much you save by reducing scrap by 50%.
Frequently Asked Questions
DPMO (Defects Per Million Opportunities) is a standardized quality metric that accounts for the complexity of a product. It is calculated as: DPMO = (Defects ÷ (Units × Opportunities per Unit)) × 1,000,000. This allows comparison across different products and processes.
Six Sigma tables map DPMO to Sigma levels. 3.4 DPMO = 6σ (99.99966%). 308,537 DPMO ≈ 2σ (69.1%). 66,807 DPMO ≈ 3σ (93.3%). 6,210 DPMO ≈ 4σ (99.38%). 233 DPMO ≈ 5σ (99.977%). This calculator provides an approximation.
First Pass Yield (FPY) is the percentage of units that pass quality inspection on the first attempt without any rework. FPY = Good units ÷ Total units. A high FPY means less rework and lower hidden costs.
The cost of quality includes: direct material cost of scrapped units, labor and machine time wasted, cost to rework repairable units, warranty and customer return costs, and lost revenue from reduced throughput. Studies suggest quality costs can equal 20–40% of revenue for poor-quality producers.
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