Diagnose · Cost flow

Cost flow

A flow diagram (Sankey) from bucket to plant to process. The width of each band is the cost that flows through it.

It shows in one picture which plants and processes the money of each bucket ends up in, which is hard to see in tables.

Follow the widest bands: that is where most cost sits. Small processes are grouped as Other sets; click it to see them.

Wide bands from prevention and appraisal and thin bands from the failure buckets, spread over plants rather than one plant carrying most failure.

The expert is reading the figures…

Concern

There is a problem here worth looking into.

Problem: Failures make up 57% of quality cost: most of the money goes to fixing problems rather than preventing them.
Watch: Prevention is 12% of quality cost, below the benchmark of 22%.
Problem: External failure is 29% of quality cost, above the benchmark of 20%.
Fact: The largest plant is Columbus, OH with 31% ($10.68M).

Computed by the app from the figures in this view. Data as of 9 Nov 2026 02:14.