Total cost of quality Demo · Cleanry About TCoQ

Diagnose

1-10-100 staircase

What it is

What it shows

The average cost per record of appraisal, internal failure and external failure, on a log scale, with how many times dearer each step is than the one before.

Why it matters in manufacturing

The 1-10-100 rule says a problem costs about ten times more at every stage it escapes. Your own figures show how true that is in your plants, and so how much finding problems earlier is worth.

How to read it

Each bar is per record of that stage, and a record is not always one defect, so read the multipliers as an order of magnitude. Large multipliers make a strong case for prevention and early detection.

What good looks like

Most problems are found early: a short bar for external failure compared with internal failure, because problems are stopped before they leave the plant.

Expert view

The expert is reading the figures…

Concern

There is a problem here worth looking into.

What we observe

  • Fact: A defect costs $26 at inspection, $279 inside the plant and $1.1k at the customer: 42 times as much once it escapes.
  • Problem: 21% of failure records are found by customers (9,356).

Keep in mind

  • One set has a record count that differs from AlisQI.
  • The token cannot read 5 sets, so the total may be partial.

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

Explanation

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Diagnose

The figure

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