Reject Rate Calculator

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Reject Rate & Quality Control Calculator

Analyze production efficiency and financial loss due to defects.

Please enter valid positive numbers. Total units must be greater than rejected units.
Reject Rate (Defect %) 0.00%
Yield Rate (Pass %) 0.00%
Total Scrap Loss $0.00
Status –

What is the Reject Rate?

The Reject Rate (also known as the defect rate or scrap rate) is a critical Key Performance Indicator (KPI) in manufacturing and quality control. it measures the percentage of units that fail to meet quality standards compared to the total number of units produced or inspected.

The Reject Rate Formula:
Reject Rate (%) = (Number of Rejected Units ÷ Total Units Produced) × 100

Why Monitoring Reject Rates Matters

A high reject rate indicates inefficiencies in the production process, machine malfunctions, or poor-quality raw materials. By tracking this metric, businesses can:

  • Reduce Operational Costs: Every rejected item represents lost material, energy, and labor time.
  • Improve Customer Satisfaction: Lower reject rates in the factory mean fewer defective products reach the end consumer.
  • Optimize Supply Chain: Identifying spikes in reject rates can help pinpoint issues with specific material batches from suppliers.

Example Calculation

Imagine a beverage bottling plant produced 50,000 bottles in a single shift. During the quality inspection, the sensors flagged 1,200 bottles for improper sealing or under-filling.

  • Total Units: 50,000
  • Rejected Units: 1,200
  • Calculation: (1,200 / 50,000) × 100 = 2.4%

In this scenario, the Reject Rate is 2.4% and the Yield Rate is 97.6%.

How to Lower Your Reject Rate

To improve production quality, consider implementing these strategies:

  1. Predictive Maintenance: Regularly service machinery to prevent malfunctions that lead to defective outputs.
  2. Staff Training: Ensure operators are well-versed in standard operating procedures (SOPs).
  3. Quality Audits: Perform frequent spot checks at different stages of the production line, not just at the end.
  4. Six Sigma Methodology: Utilize data-driven approaches to eliminate variability in the manufacturing process.
function calculateRejectRate() { var total = parseFloat(document.getElementById("totalUnits").value); var rejected = parseFloat(document.getElementById("rejectedUnits").value); var cost = parseFloat(document.getElementById("unitCost").value) || 0; var error = document.getElementById("errorMsg"); var results = document.getElementById("resultsArea"); // Validation if (isNaN(total) || isNaN(rejected) || total <= 0 || rejected total) { error.style.display = "block"; results.style.display = "none"; return; } error.style.display = "none"; // Logic var rejectRate = (rejected / total) * 100; var yieldRate = 100 – rejectRate; var totalLoss = rejected * cost; var status = ""; var statusColor = ""; if (rejectRate <= 1) { status = "Excellent (World Class)"; statusColor = "#27ae60"; } else if (rejectRate <= 3) { status = "Good (Average)"; statusColor = "#f1c40f"; } else { status = "Action Required (High Waste)"; statusColor = "#e67e22"; } // Output formatting document.getElementById("resRejectRate").innerText = rejectRate.toFixed(2) + "%"; document.getElementById("resYieldRate").innerText = yieldRate.toFixed(2) + "%"; document.getElementById("resScrapLoss").innerText = "$" + totalLoss.toLocaleString(undefined, {minimumFractionDigits: 2, maximumFractionDigits: 2}); document.getElementById("resStatus").innerText = status; document.getElementById("resStatus").style.color = statusColor; results.style.display = "block"; }

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