Cost of quality: what getting it wrong actually costs
Cost of quality adds up prevention, appraisal and failure. Why the invisible categories dominate, how to estimate them, and what the ratio tells you.
An accrual books a cost before the invoice arrives. Why that matters for monthly figures, how to decide the amount, and the accruals that quietly become permanent.
An accrual records a cost in the period that incurred it rather than the period the invoice happened to arrive in. Without accruals a month looks cheap because a supplier was slow, and the next month looks expensive for the same reason — and anybody comparing the two is reading the supplier's admin rather than the business.
Use the best estimate available at the time, and prefer a method you can repeat. A purchase order gives you the agreed price; a contract gives you a rate and a quantity; a previous invoice for the same thing gives you a usable approximation. Where nothing exists, a considered estimate recorded with its basis beats both a guess and an omission — the point of an accrual is to be approximately right rather than precisely absent. Round sensibly and do not spend an afternoon refining a figure that will be replaced by an invoice within weeks.
Reverse the accrual in the following period rather than leaving it to be netted off against the invoice. Reversing automatically is what prevents the commonest error in this area, which is double-counting the same cost once as an accrual and again when the real invoice is posted.
Ettex Sheets is enough to hold the listing — description, amount, basis, the period it relates to and what it is waiting for — which turns the monthly review into a short conversation instead of an excavation. What is actually owed sits in the creditors ledger, and the two should reconcile once the invoices land.
A cost recorded in the period it was incurred, before the invoice arrives, so that monthly figures reflect activity rather than supplier admin.
Approximately right rather than precisely absent. Use a purchase order, contract rate or previous invoice, and record the basis with the entry.
Reversing it automatically in the following period, rather than relying on somebody netting it off when the real invoice is posted.
Cost of quality adds up prevention, appraisal and failure. Why the invisible categories dominate, how to estimate them, and what the ratio tells you.
Payback period measures how quickly an investment returns its cost. How to calculate it, what it deliberately ignores, and when it is the right test.
First pass yield measures what got through without rework. Why it is harsher than scrap rate, how to calculate it across steps, and what a high figure can conceal.