COPQ Calculator

Estimate where dimensional inspection issues may be leaking margin.

Use this calculator to frame cost tied to reinspection, troubleshooting, waiting on inspection results, scrap, rework, containment, and delayed FAI, PPAP, or launch approvals.

Calculate inspection-related COPQ exposure

Use conservative estimates. The goal is not to inflate the number. The goal is to make hidden inspection waste visible enough to support a practical improvement conversation.

WeeklyLabor, CMM, and waiting waste
MonthlyScrap, rework, containment, launch delay
AnnualDirectional COPQ exposure
DriverLargest visible cost source
Use the right calculator

Running repeat-part production at volume?

This calculator is built for job-shop or high-mix inspection where programs, setups, parts, and launch work change often. If your cost problem is scrap rate, rework, customer escapes, warranty, containment, or line stoppage across repeat-part production, use the high-volume version instead.

Open the High-Volume COPQ Calculator

Rates and inspection load

Burdened hourly rate for inspection, programming, or quality support labor.
Use machine burden rate if known. Otherwise use a conservative estimate.
Estimated hourly impact when production, shipment, or launch decisions wait on inspection.
Used for context and future scaling, not to inflate the estimate automatically.

Weekly inspection waste

Use hours where production, quality disposition, shipment, or engineering decisions are delayed.

Monthly cost exposure

Estimate hours during a typical month with active launch activity. If launches happen only a few times a year rather than every month, this will overstate the annualized figure - treat the annual result as a per-launch-period estimate, not a steady 12-month run rate.

Organizational risk signal

This section does not change your calculated cost estimate above. It is a separate signal for the kind of risk that often does not show up in scrap rate, Cpk, or current cost until it is already expensive to fix.

Workarounds that feel harmless today (skipping a step under deadline pressure, using "tribal knowledge" instead of the written method) are a common early source of COPQ that won't show up in scrap rate or Cpk until much later.
Skill gaps tend to be invisible day-to-day because experienced people quietly compensate for them - until that person is out, overloaded, or moves on.
Open or recently vacated quality roles often mean institutional knowledge is leaving faster than it's being replaced, even if current output looks unaffected.
Inconsistent disposition decisions are a common source of repeat nonconformances and disputed results, even when the underlying process itself is capable.
A slow or unclear path from "problem found" to "problem resolved" lets small issues sit and compound instead of getting addressed while they're still cheap to fix.
Risk level will appear here
Organizational risk will appear here

Your estimated inspection-related COPQ exposure

Complete the inputs above, then calculate your result. No contact information is required to see the on-page estimate.

Weekly waste $0
Monthly exposure $0
Annual exposure $0

Largest visible cost driver: Cost driver will appear here.

Your organizational risk signal will appear here.
Your recommendation will appear here.

Cost driver breakdown

Cost driver Estimated monthly impact What it may indicate
Calculate your estimate to populate the breakdown.

Want the COPQ summary sent for follow-up?

Your estimate appears above after you calculate it. Enter your information only if you want Wolf Metrology to receive the summary for follow-up.

You can calculate the estimate without submitting contact information. Submitting this section sends the COPQ inputs and calculated summary to Wolf Metrology for follow-up.