Not a complaint cost sheet
The complaint cost sheet adds up the costs of one customer complaint for a debit summary, in your browser. This log is for your own scrap and rework over weeks and months, per part and reason, whether a customer saw it or not.
What is in the file
- Settings: rework cost per hour (your currency) and the repeat cut-off. The cut-off of 3 rows is our own default; change it.
- Log: ref, date, part, reason, found at (Incoming, In process, Final inspection, Customer return), scrap or rework, quantity, cost per part or rework minutes per part, NCR or 8D ref, and a separate Repeat column.
- Cost fills in: scrap is quantity times cost per part; rework is quantity times minutes, divided by 60, times the rate per hour.
- A row with a missing field shows no cost and a note on what to fill in. It stays out of the cost totals, and the number of rows left out is shown next to the totals.
- Counts under the log: rows logged, scrapped and reworked parts, scrap, rework and total cost, rows left out of the cost totals, rows per check, and rows marked repeat. No score and no ranking.
How the check is worked out
In this order; the first match wins:
| Check | When |
|---|---|
| Enter quantity | Quantity is blank. |
| Pick scrap or rework | Scrap or rework is blank. |
| Enter cost per part | A scrap row has no cost per part. |
| Enter rework minutes or the rate in Settings | A rework row has no minutes per part, or the rework cost per hour in Settings is blank. |
| Logged | None of the above. |
Repeats have their own column, so a row that is still missing data can be marked too. When the same part and the same reason are on at least your repeat cut-off rows (our default: 3), each of those rows shows "Same part and reason on N rows: worth a root cause check". It needs no quantity or cost, and stays blank when the cut-off, part or reason is blank. Repeats match the same text: capitals do not matter, spelling does. Type part and reason the same way each time.
Example (fictional)
Made-up parts and costs, extract, October 2026; the rate of 40 per hour is set for the example only, not a suggestion:
| Ref | Part | Reason | Scrap or rework | Quantity | Cost | Check | Repeat |
|---|---|---|---|---|---|---|---|
| S-01 | Housing | Burr on edge B | Rework | 40 | 160.00 | Logged | Same part and reason on 3 rows: worth a root cause check |
| S-02 | Seal | Cut on lip | Scrap | 25 | 30.00 | Logged | |
| S-03 | Housing | Burr on edge B | Rework | 30 | 120.00 | Logged | Same part and reason on 3 rows: worth a root cause check |
| S-04 | Bracket | Wrong paint shade | Scrap | 60 | Enter cost per part | ||
| S-05 | Housing | Burr on edge B | Scrap | 10 | 45.00 | Logged | Same part and reason on 3 rows: worth a root cause check |
| S-06 | Shaft | Diameter over limit | Rework | 12 | Enter rework minutes or the rate in Settings |
In the full example of 8 rows, the cost total is 355.00 from 4 rows; 4 rows are left out until their missing fields are filled in. The housing burr shows up on 3 rows (S-01, S-03, S-05), so all 3 are marked in the Repeat column; it would be marked even if those rows had no cost yet.
Worth a check each month
- Rows marked in the Repeat column: the same part and reason again. Worth a root cause check, for example with an 8D report.
- Rows left out of the cost totals: fill them in before you quote a number.
- Many rows found at final inspection or as customer returns: worth a look at where the defect could be found earlier.
Your own costing and procedure decide which costs to count. The log is an aid, not an accounting record.
Related
Advisory template, in English.