SAIKARIS
Industry Consulting Group
Free Diagnosis
For business owners and operations managers
How much are defects really
costing your business?
Four questions about your process, then your details — and you'll see exactly where you stand, what risk you carry and how much slips away every month.
1
Your business
2
Production
3
Defects
4
Detection
5
Your details
6
Results
Step 1 of 5
What industry does your company operate in?
Choose the closest match. We'll compare you against your industry average.
Please select your industry to continue.
What kind of product or service do you make?
e.g. "injection-moulded plastic parts", "e-commerce orders", "refrigerated pallet shipments"…
Step 2 of 5
How much do you produce and at what price?
We need your monthly volume and unit value to calculate the real financial impact of your defects.
Please enter the number of units you produce per month.
Step 3 of 5
How many defects do you have?
An honest estimate is enough. If you don't track this yet, that itself tells us something important.
Units that fail first inspection but can be recovered — reworked, repainted, reassembled…
👉 Enter 0 if unsure — we'll continue anyway.
No recovery path — defective material, broken parts, out-of-spec products that go straight to waste.
Total units with issues: — · —
What kind of defects are these?
Choose the type that best matches your typical failure.
How often do these defects appear?
Drag to where it feels right — 1 = almost never, 10 = all the time.
5
1 — Almost never5 — Occasionally10 — All the time
Occasional — visible but manageable if caught early.
Please enter at least one value (can be 0).
Step 4 of 5
How do you detect defects?
This determines how many defects reach your customer — and how much damage they cause.
Please select your detection method.
Step 5 of 5 — Almost there
Who are we talking to?
Your diagnosis is calculated and waiting. Tell us who you are and we'll reveal your full results immediately.
Please fill in your name, company and a valid email address.
🔒 Your data is confidential and never shared with third parties.
Your quality level
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—
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sigma level
Where you stand among companies in your sector
Sigma level distribution — your sector
How do you compare to other industries?
Your position on the industrial quality spectrum
Out of every 1,000 units…
how many have a defect? (lower is better)
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with defectsFirst-pass yield
% produced right first time — no rework, no scrap
—
%You rework per month
units consuming extra time and resources
—
You scrap per month
unrecoverable units — production cost lost
—
Calculated reputational risk
—
—
out of 100
Defects reaching the customer
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Detection method
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% output exposed
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Exposure index
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Defect type / gravity
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Perceived frequency
—
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What this is costing you in euros
Monthly estimate based on the data you provided
Total cost of defects / month
scrap + rework + reputational factor
—
If nothing changes, in one year
×12 months
—
Scrapped material only
production cost of everything thrown away
—
Rework cost only
extra labour and materials to fix defects
—
—
Ready to go from knowing the problem to solving it?
These numbers have a solution.
Our team has worked in over 40 industrial plants. We help you identify the real root causes and build a concrete improvement plan.