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SyteLine Scrap, Yield and Job Start Quantity Calculator

Planners need to know how many pieces to start so that the right number of good units come out. Yield and scrap factors in the routing and BOM drive that number, and small yield losses compound quickly across operations.

Your numbers

Good units required

units

Yield, operation 1

98 %

Yield, operation 2

95 %

Yield, operation 3

99 %

Average cost of a scrapped piece

Accumulated cost at the point it is scrapped.

Your results

Rolled throughput yield

92.2%

Pieces to start

543

Expected scrap units

Overall scrap rate

7.9%

Scrap cost per job

$1,806

Assumes yields are independent and that scrap is not reworked. Replace with real operation yield data from your shop floor reporting.

Save results:

Pieces to start vs operation 2 yield

Sweeps Yield, operation 2 from 80 to 100, holding your other inputs fixed.

Planned vs actual yield analysis

Optional: we can compare the yield assumptions in your routings against actual job results.

Optional. The tool and every export work without this. No spam.

How to use it

Enter the good units the order needs and the first pass yield of each of three operations, as percentages. The tool multiplies them to give rolled throughput yield, then divides the need by that fraction to give the pieces to start. It also shows expected scrap units and cost, using the average accumulated cost of a scrapped piece. Slide the middle yield in the chart to see how sensitive the start quantity is to your weakest step.

Use first pass yield, excluding pieces fixed by rework
Collect yield from real job transaction data where possible
Combine operations that always scrap together

Method

Rolled throughput yield is the product of the individual operation yields. Pieces to start equal good units required divided by that product, rounded up. Three operations at 98%, 95% and 99% sound healthy but roll up to about 92.2%, so a 500 unit order needs about 543 pieces started. Setting yield or scrap factors in SyteLine routings and items lets job and MRP calculations gross up the same way.

Common mistakes

Averaging yields instead of multiplying them understates scrap. Entering a scrap factor on both the BOM component and the routing operation double counts the loss. Scrap discovered late costs far more than early scrap, so a flat per unit scrap cost is only an average. Finally, a yield that reflects rework hides labor cost, so track first pass and final yield separately.

Do not apply scrap at both BOM and routing level for the same loss
Review yields after process or supplier changes
Weight the scrap cost by where in the routing scrap occurs

Frequently Asked Questions

What is the difference between yield and scrap percent?

Yield is the share of started units that are good, scrap is the remainder. A 5% scrap rate equals 95% yield. Make sure you know which one a given field expects.

Why not just add up scrap percentages?

Because each operation only scraps what reaches it. Multiplying yields gives the exact effect, adding percentages is only close when losses are tiny.

How accurate is the scrap cost?

It is an average. Real cost depends on where the part fails, since later scrap carries more labor and material. Use a weighted average if you have scrap by operation.

Does this work for process industries?

The yield math applies, but process batches often use yield by step in the formula or recipe. Adjust inputs to match how your plant reports yield.

If you want actual yield and scrap by operation extracted from your SyteLine job history and compared with planned values, we can build that report.

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