NetSuite Component Yield and Scrap Requirement Calculator
Component yield and scrap are easy to set and easy to misread. This calculator shows how much of a part you really need for a build and what the losses cost.
Your numbers
Quantity on the bill of materials line.
Percent of the component that ends up usable. 100 means no loss.
Pieces expected to be lost proving the setup.
Your results
Planning aid using the simple relation required = gross / yield + setup scrap. Check how your NetSuite BOM component yield and any scrap settings are applied in your account before comparing results.
Total requirement vs component yield
Sweeps Component yield from 60 to 100, holding your other inputs fixed.
Compare planned yield to actual usage
Optional: we can discuss comparing BOM yield with actual component issues in your NetSuite data.
Optional. The tool and every export work without this. No spam.
How to use the calculator
Enter the number of assemblies to build, the quantity per assembly from the BOM line, and the expected yield of that component. Add pieces lost in setup and the pieces you hold. The result is the total requirement, the shortage and the cost tied up in losses. Move the yield slider to see how sensitive the requirement is, and read the chart for the same sweep.
- Use the BOM line quantity, not the assembly total
- Enter yield as a percent of good pieces
- Setup scrap is per work order, not per unit
- Check shortage against available, not on order
The formula
Gross requirement is build quantity times quantity per assembly. With a yield of 95 percent, you must start with gross divided by 0.95 to end with enough good pieces, which is more than gross times 1.05. Setup scrap is added after that, and the result is rounded up to whole pieces. For 500 units at 2 per unit, 95 percent yield and 4 setup pieces, the requirement is 1,000 / 0.95 + 4, rounded up to 1,057.
Yield versus scrap percent
A 5 percent scrap allowance multiplies gross by 1.05, while a 95 percent yield divides by 0.95, so the second produces a slightly higher number. The difference grows as losses grow. Know which one your BOM uses and apply it consistently. NetSuite lets you set component yield on BOM lines, so this calculator is a good way to sanity check the figures work orders produce.
Common mistakes
Applying the same yield to every component, forgetting that setup scrap does not scale with quantity, and rounding down. Rounding down is the worst error because it creates a shortage mid-run. Also remember that losses happen at different steps. A part lost in the final operation costs the full assembly, not just the component.
Frequently Asked Questions
Is yield the same as a scrap percentage?
No. Yield divides the required quantity, while a scrap percentage multiplies it. At 5 percent loss, yield gives about 5.3 percent extra material, so check which one your BOM and policy use.
Why add setup scrap separately?
Setup losses happen once per work order regardless of quantity, so they should not be a percentage. For small lots, setup scrap can be larger than the yield loss.
Does NetSuite round the result?
Rounding depends on the item units, precision and your configuration. This calculator rounds up to whole pieces, which is conservative for planning.
How do I find the real yield?
Compare quantity issued against quantity built on closed work orders over several months. The ratio shows actual yield, and variances point to operations that need attention.
If you want yield assumptions compared with actual component consumption in NetSuite, Netray can discuss a read-only analysis of work order issues and builds.
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