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.
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.
Payback period is the time it takes for an investment to return the cash it consumed. It is the crudest of the investment measures and the most used, because it answers the question a small business actually asks — how long before this stops being a hole in the bank account — rather than the question textbooks prefer.
Everything after the payback point, which is its central weakness. A machine paying back in two years and lasting three is worse than one paying back in three years and lasting fifteen, and payback period cannot see the difference. It also ignores the time value of money and any residual value at disposal. That makes it a poor sole criterion for large or long-lived purchases — and a perfectly reasonable screen for small ones, where the analysis should not cost more than the decision.
Be sceptical of savings that depend on somebody having spare time afterwards. «This saves four hours a week» is only cash if those four hours are removed from a wage bill or sold to a customer; otherwise it is a genuine improvement in working life that belongs in a different column of the argument.
Ettex Sheets holds the cumulative cash profile month by month, which is both the calculation and the sanity check — seeing the line cross zero is more informative than the single figure it produces. Where the purchase is large enough to matter, the same sheet should carry the assumptions, since those are what any later review will question.
Total cash out divided by cash in per period, or cumulatively month by month where returns are uneven. Use incremental cash amounts, not accounting profit.
It ignores everything after the payback point, along with the time value of money and residual value — so it cannot distinguish a short-lived asset from a long-lived one.
For small purchases, short-lived technology and genuine cash constraints. Longer or strategic decisions need a discounted measure.
Cost of quality adds up prevention, appraisal and failure. Why the invisible categories dominate, how to estimate them, and what the ratio tells you.
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.
Lead time is how long something actually takes from order to arrival. How to measure it rather than quote it, why the average is the wrong figure, and what variation costs.