Free tool

What does poor quality really cost you?

Internal scrap, returns and recalls weigh on margin far more than they seem. Enter your numbers and find out in 30 seconds the annual cost of poor quality — and how much you could recover with in-line quality control.

How it works (in brief)

Not all defects cost the same: it depends on where you find them.

Defect caught in the factory → you only lose the cost of the part (you scrap it).
Defect that reaches the customer → you lose the part plus the cost of handling the return/recall (logistics, replacement, paperwork, reputation): much more expensive.

That's why there's the field "Defects that reach the customer (%)": it indicates how many of the non-conforming parts escape your controls and end up at the customer. The rest you catch internally.

Example

500,000 parts/year with a 2% defect rate = 10,000 defective parts. If 15% reaches the customer → 1.500 become returns and 8.500 you scrap in the factory.
Internal scrap: 8,500 × €4 = 34.000 € · Returns/recalls: 1,500 × (€4 + €120) = 186.000 € · Total ≈ €220,000/year.

Your numbers

Indicative estimates: use the values you know, even approximate ones.

Parts produced per year

pcs/year

Defect rate (% non-conforming parts)

Production cost per part

€

Defects that reach the customer (% of non-conforming)

Average cost of a return / recall

€

The cost of poor quality

Internal scrap—

Returns and recalls from the customer—

Estimated total cost / year—

Potential savings with in-line control

—

Estimate based on a reduction of up to 70% in scrap and returns thanks to early in-line defect detection (FIXS X-ray architecture).

Why it matters

Poor quality is a hidden cost, not a one-off

Every defective part you scrap — or worse, that reaches the customer — erodes margin, reputation and production capacity. The point isn't to "inspect more", but to inspect at the right moment: in-line, on every part, even where the defect isn't visible to the eye.

Invisible internal defects

Porosity, cracks, weld defects: 3D X-ray imaging finds them where visual inspection can't reach.

In-line control, 100%

Not by sampling: inspection of every part, at production speed.

Less scrap, fewer returns

You catch the defect before it becomes a return, a recall or a line stoppage.

Do these numbers worry you?

In-line X-ray quality control with the patented FIXS architecture is designed precisely to cut these costs. Tell us about your process: together, with data, we assess how much you can recover.

Request a free assessment →