What Rework Is Really Costing You (rebuilt Sept 8, 2026)

Redone cuts, refinished pieces, callback trips, scrapped material. A full-time salary walking out the door in sawdust — with 82% of it in the failure buckets, because this shop, like most, buys failure retail while funding prevention with pocket change.

How it works

• The Four Buckets — internal failure, external failure, appraisal, prevention, priced for one honest month. The ratio is the diagnosis
• The Defect Log — a month of defects by category → first-pass yield (81.3% in the sample), DPMO, an honest sigma level, and the Pareto truth: two of six categories carry half the cost
• The Fix List — each fix priced against the defects it kills. The sample's three fixes — a stop jig and checklist, spec sheets on work orders, dust control — return $1,063 a month on $1,250 invested, with the first one paying back in 19 days

Built for

Cabinet and wood shops · auto body · machine and job shops · print and sign shops · trades with callbacks · anyone who has ever made the same part twice for one invoice.

What you get

One .xlsx file, four tabs, instant download. Excel, Google Sheets, Apple Numbers, LibreOffice. No macros, no subscription. Real quality-engineering math (COPQ, DPMO, sigma) without the consultant.