Cost of poor quality & ROI calculator

Enter a few numbers from your plant to see what poor quality costs you each month — and what digital inspections and faster CAPA could save.

Scrapped units per month

Cost per scrapped unit — material + processing (₹)

Reworked units per month

Cost per rework — labour + machine time (₹)

Customer returns / complaints per month

Cost per return — freight, sorting, penalties (₹)

Hours per week on paper checklists & reports

Loaded cost per staff hour (₹)

Expected defect reduction with QCIN (%)

Expected paperwork time saved (%)

Your cost of poor quality (COPQ)

₹2,34,310 / month

Scrap₹90,000
Rework₹24,000
External failure (returns / complaints)₹90,000
Appraisal (manual inspection paperwork)₹30,310

Estimated potential savings

₹55,955 / month

≈ 22.4× return on the Starter plan (₹2,499/month) · pays back in about 2 days.

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Show the calculation

Scrap = 600 × ₹150 = ₹90,000
Rework = 400 × ₹60 = ₹24,000
Returns = 6 × ₹15000 = ₹90,000
Paperwork = 20 h/week × 4.33 × ₹350 = ₹30,310
COPQ = sum of the above = ₹2,34,310
Savings = (₹2,04,000) × 20% + ₹30,310 × 50% = ₹55,955
ROI = savings ÷ plan price ₹2,499 = 22.4×

Estimates only, not a guarantee — based on the figures and improvement assumptions you entered. Actual results depend on your processes.