Quality escape cost calculator
An assembly error costs more the later it is found. Enter your plant's numbers to see what errors from manual stations cost you per year, and what changes if a share of them is caught at the station instead.
Your numbers
Method
How the numbers work
Each error that leaves a manual station is priced where it is finally found. At the next station or at final inspection it costs one unit's rework. At the customer it costs a whole escape: sorting, containment, warranty and 8D effort.
The example values follow a common rule of thumb: an error that costs 1 to fix at the station costs about 10 at the next step, 100 at final inspection and 1,000 or more at the customer. In real plants the last step is often much steeper. One US OEM told us a 20-dollar part turned into a 1.2 to 1.5 million dollar escape.
With Trenon, the chosen share of errors is caught at the station, where fixing them costs seconds instead.
FAQ
Questions
What counts as an error that leaves the station?
A step that was skipped or done wrong and that the operator did not notice: a missing clip, a connector not fully seated, a wrong variant. Count the ones found later, not the ones fixed on the spot.
Does the calculator store my numbers?
No. The calculation runs in your browser. Nothing you enter is sent anywhere.
How do I catch more errors at the station?
Verify each critical step while it is performed and tell the operator immediately when something is missing or wrong. Trenon does this with a camera at the station, worn by the operator or mounted, and an alert to the operator.
Related
Pilot
Start with one station
Bring one manual assembly station. In 30 minutes we tell you which checks Trenon can verify there and what a three-week pilot looks like.
Book a 30-minute callWith Nadir Harouak, CEO. Or write to hello@trenon.ai.