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What would cutting scrap actually save?
Scrap hides in cost-of-goods where nobody owns it. Three inputs give you the annual number; the scenarios show what root-cause ML programs report recovering.
Inputs
All units entering the process
Typical discrete/process plants: 1–5%
Material + labor + energy + disposal
The math. Annual scrap cost = units × scrap rate × cost/unit. Scenarios apply 30% (typical ML root-cause result) and 58% (best vendor-reported published deployment).
Readout
Annual scrap cost—
Saved at −30% (typical ML result)—
Saved at −58% (best published)—
Context: ML root-cause programs commonly report 10–30% scrap reductions; the best published vendor-reported deployment reached −58% (JEMBA). The share of your scrap with unknown causes is the share ML can attack.
Next stepTake the number to the Cutting scrap: attack the unknown-cause share playbook, or get the ROI workbook — all four calculators in one sheet, with scenario columns, for your budget meeting.
Free ROI workbook
Leave with the number, not a bookmark.
All four loss calculators — downtime, OEE, scrap, energy — in one Excel sheet, with conservative / typical / best-published scenario columns. Built for your budget meeting.
It's yours.