Rework and Waste from Undetected Glass Defects Due to Manual Inspection

$100,000-$180,000 annually in field replacements, warranty claims, reputational damage, and test lab costs • $110,000-$200,000 annually in scrap, rework batches, regulatory penalties, recall logistics, and customer goodwill loss • $120,000-$200,000 annually in scrap, rework, and appliance warranty claims from undetected defects

Cost controller manually cross-references batch numbers with inspection notes; sends urgent emails to production and quality asking for batch containment data; tracks recall cost in spreadsheet • Cost controller manually reconciles scrap invoices with production logs; sends email queries to operations asking for root cause of high defect rates; tracks in spreadsheet variance analysis • Cost controller manually reconciles scrap invoices with production logs; sends Excel-based inquiries to production asking for root cause of defects; tracks in variance spreadsheet