How to use this calculator
- Choose one clearly defined production window.
- Enter values recorded for that same window.
- Select Calculate and review the main result.
- Use the supporting figures to identify the next check.
#2138 · Logistics & Manufacturing Tool
Welding Cell Yield Loss Calculator
Use this welding cell yield loss calculator to turn routine welding production records into a clear operating measure. Enter values from one consistent production window to see the main result, supporting rates or gaps, and a concise interpretation. The page keeps assumptions visible so shift-to-shift comparisons are easier to audit.
Calculator
Production inputsFormula
Yield loss rate = (Units started − Good units) ÷ Units started × 100%
Estimated loss cost = lost units × cost per started unit.
What the result means
Yield loss measures the share of started units that did not become accepted output. It can include scrap, failed builds, or other losses depending on your counting rule.
If reworked units are counted as good, state that explicitly; otherwise comparisons across teams may be misleading.
Example calculation
If 500 units start and 465 are accepted, 35 units are lost. Yield loss is 35 ÷ 500 × 100 = 7.00%. At $8.50 per started unit, estimated loss cost is $297.50.
Tips for better results
- Use one consistent time boundary for every input.
- Keep planned time, run time, and output definitions documented.
- Compare like products and similar staffing conditions.
- Investigate component losses before changing a target.
- Recalculate after process changes using a fresh measurement window.
Frequently asked questions
Should rework count as yield loss?
That depends on your counting rule. For first-pass yield, units needing rework are not good units.
Can yield loss be zero?
Yes. It is zero when every started unit is accepted under the chosen quality rule.
Why include cost per started unit?
It converts lost units into a simple estimated cost for prioritization.
Does estimated loss cost include labor and overhead?
Only if those amounts are included in the unit cost you enter.
What if good units exceed units started?
The calculator rejects that input because it is inconsistent for a single measured process window.
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Result reference
| Measure | Use |
|---|---|
| First-pass yield | Calculated from the production values entered above. |
| Units lost | Calculated from the production values entered above. |
| Estimated loss cost | Calculated from the production values entered above. |