Cost of Poor Quality     
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The COPQ is the sum spent on prevention, appraisal and failure costs. There are four categories of costs: internal failure costs (costs associated with defects found before the customer receives the product or service); external failure costs (costs associated with defects found after the customer receives the product or service); appraisal costs (costs incurred to determine the degree of conformance to quality requirements); and prevention costs (costs incurred to keep failure and appraisal costs to a minimum).

Examples

bulletPrevention - quality planning  (testing, inspection, audits and process control), policies and procedures, new design reviews, in process inspections and testing, supplier quality evaluations, education and training.

bulletAppraisal. Inspection and testing, product quality audits.

bullet Failure. Includes external and internal. External includes warranty charges, complaint adjustments, returned material, allowances. Internal includes scrap, rework, failure analysis, re-inspection and re-testing, downgrading.

General Rule of Thumb
 " Ounce of prevention is worth a pound of cure"

 Costs one dollar ($1.00)  to prevent a problem, $10.00 to find it and $100.00 and more to fix it -- recognizing that not all failure costs can be captured.


More Information

 Principles of Quality Costs: Principles, Implementation, and Use, Third Edition  Campanella, Jack, editor. ASQ Press. Item: H1013 219 pages. ISBN 0-87389-443-X. 6 X 9 Hardcover. 1999. (800) 248-1946