🇦🇪UAE

تكاليف الاختبار المتكررة والفحوصات الإضافية (Repeated Testing & Redundant Inspection Costs)

Updated: Feb 20262 verified sources

Definition

Per evidence, 'QCC-approved laboratories conduct safety, performance, and quality tests'[1] and 'products that fail to meet standards may require retesting or modifications'[1]. Typical test costs for mechanical/fastener products: Tensile testing AED 2,000–3,000 per batch; hardness testing AED 1,500–2,500; dimensional/surface inspection AED 1,000–2,000; total per cycle = AED 4,500–7,500. A single batch may undergo 2–3 test cycles if root cause is not identified. Additionally, factory inspections ('on-site audits to verify quality control systems'[1]) cost AED 8,000–15,000 per audit. Supplier QMS audits (if supplier documentation is insufficient) cost AED 5,000–10,000 each.

Key Findings

Financial Impact: LOGIC Estimate: AED 80,000–250,000 annually. Breakdown: (1) Redundant testing: 12–20 failed batches/year × 1.5–2 re-test cycles × AED 5,000/cycle = AED 90,000–200,000. (2) Factory re-inspections: 1–2 per year × AED 8,000–15,000 = AED 8,000–30,000. (3) Supplier audits (extra): 2–4 per year × AED 6,000 = AED 12,000–24,000. Total: AED 110,000–254,000.
Frequency: Quarterly and ad-hoc; triggered by certification failures and audit findings
Root Cause: Raw material supplier variability; lack of incoming material SPC; missing traceability links between supplier lot → production batch → test result; insufficient supplier QMS pre-qualification

Why This Matters

This pain point represents a significant opportunity for B2B solutions targeting Turned Products and Fastener Manufacturing.

Affected Stakeholders

Quality Manager, Materials Manager, Procurement Manager, Finance Manager, Supplier Quality Engineer

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Financial Impact

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

تكاليف إعادة المعالجة والخردة للمنتجات غير المطابقة (Rework & Scrap Costs for Non-Conforming Materials)

LOGIC Estimate: AED 200,000–600,000 annually. Breakdown: (1) Rework labor: 400–800 excess hours/year × AED 250/hour (including overhead) = AED 100,000–200,000. (2) Scrap material loss: 2–5% of monthly turnover held in non-conforming inventory for 10–30 days = AED 80,000–300,000. (3) Storage/handling: AED 20,000–100,000. (4) Lost sales due to capacity absorbed by rework: AED 50,000–150,000.

فقدان الإنتاجية بسبب عمليات المراجعة والتصرف اليدوية (Capacity Loss from Manual Non-Conformance Disposition)

LOGIC Estimate: AED 250,000–750,000 annually. Calculation: (1) Average non-conformance batches: 8–12 per month = 96–144 per year. (2) Average disposition delay: 4–7 days per batch. (3) Lost throughput per day: AED 2,500–5,000 per line. (4) Estimated annual capacity loss: 384–1,008 idle line-days × AED 2,500–5,000 = AED 960,000–5,040,000. Conservative midpoint applied (30% realization): AED 250,000–750,000.

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