Cost of Poor Quality
Enter your annual figures to compute COPQ exposure, compare against the measured survey core, and model your savings potential.
Revenue Baseline
Internal Failure Rates
External Failure Costs
What is COPQ?
Cost of Poor Quality (COPQ) is the total cost incurred from producing defective products. Measured surveys put total quality costs at 2.5–5% of sales revenue; the often-quoted 15–30% band is a 1950s rule of thumb with no modern sample. Leading plants hold COPQ under 2%.
Enter data on the left to see your COPQ analysis
How to Use This Calculator
- 01Annual Revenue: Your total annual revenue in EUR.
- 02Scrap Rate: Percentage of production that becomes scrap.
- 03Rework Rate: Percentage of production requiring rework.
- 04Premium Freight: Annual cost of expedited shipments due to quality issues.
- 05Customer Claims: Annual warranty and customer complaint costs.
- 06Inspection Costs: Labour costs for quality inspection and sorting.
Industry Benchmarks
Grading bands follow the measured survey core — total quality costs of 2.5–5% of revenue — not the folklore range.
Excellent · < 2%
Ahead of the measured range
Good · 2–3%
Above average for automotive
Warning · 3–5%
Industry average — room to improve
Critical · > 5%
Significant cost reduction opportunity