Cost of Poor Quality (COPQ) Calculator

ANA›Life Services Authority›National Calculator Authority›Cost of Poor Quality (COPQ) Calculator

.calc-container { max-width: 640px; margin: 2rem 0; padding: 1.5rem; background: #fff; border: 1px solid #ddd; border-radius: 8px; box-shadow: 0 1px 3px rgba(0,0,0,0.06); font-family: system-ui, -apple-system, sans-serif; } .calc-container h3 { font-family: Georgia, serif; font-size: 1.15rem; color: #1a1a1a; margin-bottom: 1rem; padding-bottom: 0.5rem; border-bottom: 2px solid var(--ac, #3d5a80); } .calc-row { display: flex; align-items: center; gap: 0.75rem; margin-bottom: 0.75rem; flex-wrap: wrap; } .calc-row label { min-width: 160px; font-size: 0.9rem; color: #333; font-weight: 500; } .calc-row input[type="number"], .calc-row select { flex: 1; min-width: 120px; max-width: 200px; padding: 0.5rem 0.6rem; border: 1px solid #ccc; border-radius: 4px; font-size: 0.9rem; font-family: system-ui, sans-serif; color: #1a1a1a; background: #fafaf8; } .calc-row input:focus, .calc-row select:focus { outline: none; border-color: var(--ac, #3d5a80); box-shadow: 0 0 0 2px rgba(26,74,138,0.12); } .calc-row .unit { font-size: 0.82rem; color: #888; min-width: 30px; } .calc-btn { display: inline-block; margin-top: 0.5rem; padding: 0.55rem 1.5rem; background: var(--ac, #3d5a80); color: #fff; border: none; border-radius: 4px; font-size: 0.9rem; font-weight: 600; cursor: pointer; font-family: system-ui, sans-serif; } .calc-btn:hover { opacity: 0.9; } .calc-result { margin-top: 1.25rem; padding: 1rem 1.25rem; background: #f0f6fc; border-left: 3px solid var(--ac, #3d5a80); border-radius: 0 6px 6px 0; display: none; } .calc-result.visible { display: block; } .calc-result-label { font-size: 0.78rem; text-transform: uppercase; letter-spacing: 0.06em; color: #666; margin-bottom: 0.25rem; } .calc-result-value { font-size: 1.6rem; font-weight: 700; color: var(--ac, #3d5a80); } .calc-result-detail { font-size: 0.85rem; color: #555; margin-top: 0.5rem; line-height: 1.5; } .calc-note { margin-top: 1rem; font-size: 0.8rem; color: #888; font-style: italic; } .calc-grid { display: grid; grid-template-columns: 1fr 1fr; gap: 0.75rem; margin-top: 0.75rem; } .calc-grid-item { padding: 0.6rem 0.8rem; background: #f8f9fa; border-radius: 4px; border: 1px solid #eee; } .calc-grid-item .label { font-size: 0.75rem; color: #888; text-transform: uppercase; letter-spacing: 0.04em; } .calc-grid-item .value { font-size: 1.1rem; font-weight: 600; color: #1a1a1a; } @media (max-width: 720px) { .calc-row { flex-direction: column; align-items: flex-start; gap: 0.3rem; } .calc-row label { min-width: auto; } .calc-row input[type="number"], .calc-row select { max-width: 100%; width: 100%; } .calc-grid { grid-template-columns: 1fr; } } .calc-chart { margin: 1rem 0; text-align: center; } .calc-chart svg { max-width: 100%; height: auto; } .calc-chart-legend { display: flex; flex-wrap: wrap; justify-content: center; gap: 0.6rem 1.2rem; margin-top: 0.6rem; font-size: 0.8rem; color: #555; } .calc-chart-legend span { display: inline-flex; align-items: center; gap: 0.3rem; } .calc-chart-legend i { display: inline-block; width: 10px; height: 10px; border-radius: 2px; font-style: normal; } .calc-related { max-width: 640px; margin: 2rem 0 1rem; padding: 1.25rem 1.5rem; background: #f8f9fa; border: 1px solid #e8e8e8; border-radius: 8px; } .calc-related h3 { font-family: Georgia, serif; font-size: 1rem; color: #1a1a1a; margin: 0 0 0.75rem; padding-bottom: 0.4rem; border-bottom: 2px solid var(--ac, #3d5a80); } .calc-related-list { list-style: none; padding: 0; margin: 0 0 0.75rem; display: grid; grid-template-columns: 1fr 1fr; gap: 0.4rem 1.5rem; } .calc-related-list li a { font-size: 0.88rem; color: var(--ac, #3d5a80); text-decoration: none; } .calc-related-list li a:hover { text-decoration: underline; } .calc-browse-all { margin: 0.5rem 0 0; font-size: 0.9rem; font-weight: 600; } .calc-browse-all a { color: var(--ac, #3d5a80); text-decoration: none; } .calc-browse-all a:hover { text-decoration: underline; } @media (max-width: 720px) { .calc-related-list { grid-template-columns: 1fr; } }

Cost of Poor Quality (COPQ) Calculator

Calculate the total Cost of Poor Quality (COPQ) by summing internal failure costs, external failure costs, appraisal costs, and prevention costs across your organization.

### Internal Failure Costs

Costs from defects found before the product/service reaches the customer.

Scrap Costs ($)

Rework / Repair Costs ($)

Re-inspection / Re-testing Costs ($)

Downtime Due to Defects ($)

Yield Loss / Waste ($)

### External Failure Costs

Costs from defects found after the product/service reaches the customer.

Warranty Claims / Returns ($)

Customer Complaint Handling ($)

Product Liability / Legal Costs ($)

Lost Sales / Lost Customers (Estimated $)

Field Service / Recall Costs ($)

### Appraisal Costs

Costs of measuring, evaluating, and auditing quality.

Inspection & Testing Costs ($)

Quality Audits ($)

Test Equipment Calibration & Maintenance ($)

Supplier Evaluation / Incoming Inspection ($)

### Prevention Costs

Costs of activities to prevent defects from occurring.

Quality Training ($)

Process Improvement / Six Sigma Projects ($)

Quality Planning & System Development ($)

Preventive Maintenance ($)

### Revenue Reference (Optional)

Total Revenue / Sales ($) (for COPQ as % of revenue)

Calculate COPQ

function cosVal(id) { var v = parseFloat(document.getElementById(id).value); return (isNaN(v) || v 0; }); if (!anyEntered) { var res = document.getElementById('cos-result'); res.style.display = 'block'; res.innerHTML = '⚠ Please enter at least one cost value greater than zero.'; return; }

// Category Totals var internalTotal = scrap + rework + reinspect + downtime + yieldLoss; var externalTotal = warranty + complaints + liability + lostSales + field; var appraisalTotal = inspection + audit + equip + supplier; var preventionTotal= training + process + planning + preventive;

// COPQ = Internal + External + Appraisal + Prevention // Note: Some frameworks exclude prevention from COPQ (treating it as a "good" cost). // We include all four PAF (Prevention-Appraisal-Failure) categories per ASQ standard. var copqTotal = internalTotal + externalTotal + appraisalTotal + preventionTotal;

// Failure Cost (Internal + External) — the "hidden factory" cost var failureTotal = internalTotal + externalTotal;

// COPQ as % of revenue var copqPct = (revenue > 0) ? (copqTotal / revenue) * 100 : null; var failurePct = (revenue > 0) ? (failureTotal / revenue) * 100 : null;

// Category percentages of COPQ var internalPct = (copqTotal > 0) ? (internalTotal / copqTotal) * 100 : 0; var externalPct = (copqTotal > 0) ? (externalTotal / copqTotal) * 100 : 0; var appraisalPct = (copqTotal > 0) ? (appraisalTotal / copqTotal) * 100 : 0; var preventionPct= (copqTotal > 0) ? (preventionTotal/ copqTotal) * 100 : 0;

// Benchmark guidance (ASQ: COPQ typically 5–30% of revenue for most companies) var benchmarkMsg = ''; if (copqPct !== null) { if (copqPct ' + ''; }

var html = '### COPQ Results ';

html += ''; html += '' + 'Category' + 'Amount ($)' + '% of COPQ' + '';

var rows = [ ['Internal Failure Costs', internalTotal, internalPct, '#e74c3c'], ['External Failure Costs', externalTotal, externalPct, '#e67e22'], ['Appraisal Costs', appraisalTotal, appraisalPct, '#3498db'], ['Prevention Costs', preventionTotal,preventionPct,'#27ae60'], ];

rows.forEach(function(r, i) { var bg = (i % 2 === 0) ? '#f9f9f9' : '#fff'; html += '' + '' + r[0] + '' + '$' + cosFmt(r[1]) + '' + '' + r[2].toFixed(1) + '%' + ''; html += '' + bar(r[2], r[3]) + ''; });

html += '' + 'Total COPQ' + '$' + cosFmt(copqTotal) + '' + '100%' + ''; html += '';

html += ''; html += 'Total Failure Cost (Internal + External): $' + cosFmt(failureTotal); if (failurePct !== null) { html += '  |  ' + failurePct.toFixed(2) + '% of Revenue'; } html += 'This is the "hidden factory" — the cost of not doing things right the first time.'; html += '';

if (copqPct !== null) { html += ''; html += 'COPQ as % of Revenue: ' + copqPct.toFixed(2) + '%'; html += ''; }

if (benchmarkMsg) { html += ''; html += benchmarkMsg; html += ''; }

// Breakdown detail table html += '▶ View Full Cost Breakdown'; html += ''; html += 'Line ItemAmount ($)';

var details = [ ['— Scrap', scrap], ['— Rework / Repair', rework], ['— Re-inspection / Re-testing', reinspect], ['— Downtime Due to Defects', downtime], ['— Yield Loss / Waste', yieldLoss], ['— Warranty Claims / Returns', warranty], ['— Customer Complaint Handling', complaints], ['— Product Liability / Legal', liability], ['— Lost Sales / Lost Customers', lostSales], ['— Field Service / Recall', field], ['— Inspection & Testing', inspection], ['— Quality Audits', audit], ['— Equipment Calibration', equip], ['— Supplier Evaluation', supplier], ['— Quality Training', training], ['— Process Improvement', process], ['— Quality Planning', planning], ['— Preventive Maintenance', preventive], ];

details.forEach(function(d, i) { if (d[1] > 0) { var bg = (i % 2 === 0) ? '#fafafa' : '#fff'; html += '' + d[0] + '' + '$' + cosFmt(d[1]) + ''; } });

html += '';

var res = document.getElementById('cos-result'); res.style.display = 'block'; res.innerHTML = html; }

#### Formula

COPQ = Internal Failure Costs + External Failure Costs + Appraisal Costs + Prevention Costs

Based on the PAF (Prevention–Appraisal–Failure) Model (Feigenbaum, 1956; ASQ):

#### Assumptions & References

More Calculators

Read Next

Study Time Planner Authority Network America › Life Services Authority › National Calculator Authority .calc-container { max-width: 640px;...

References

Related Authorities

Life Services Authority › Professional Services Authority › Trade Services Authority › United States Authority ›