🇦🇺Australia

Cost of Poor Quality

1 verified sources

Definition

Color matching failures cause weighing errors, poor pigment heat resistance, raw material inconsistencies, and incompatibility leading to breakage and reduced melt flow.

Key Findings

  • Financial Impact: AUD 20,000-100,000/year in material waste and rework (2-5% of production costs for mid-sized firm)
  • Frequency: Per production batch or monthly
  • Root Cause: Manual trial-and-error in spectrophotometric readings, formula generation, and testing

Why This Matters

The Pitch: Plastics manufacturers in Australia 🇦🇺 waste AUD 50,000+ annually on rework and scrap from color mismatches. Automation of color matching eliminates this risk.

Affected Stakeholders

Production Manager, Quality Control, Process Engineer

Deep Analysis (Premium)

Financial Impact

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Current Workarounds

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Methodology & Sources

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

Evidence Sources:

Related Business Risks

Waste from Trial-and-Error

AUD 10,000-50,000/year in scrapped materials and labor (1-3% of material costs)

Capacity Loss from Rework

AUD 15,000-60,000/year (40 hours/month downtime at AUD 100/hour machine rate)

PPAP-Bottlenecks und Freigabe-Verzögerungen

Logikbasiert: ca. AUD 50.000–150.000 entgangener Umsatz pro Jahr durch 1–2 Monate verspätete Serienfreigaben infolge unvollständiger/fehlerhafter PPAP-Sets; zusätzlich ca. 40–80 Maschinenstunden/Jahr ungenutzte Kapazität pro kritischem Projekt.

Überhöhte PPAP-Bearbeitungskosten und Doppelarbeit

Logikbasiert: ca. 400–1.000 zusätzliche Arbeitsstunden pro Jahr für manuelle PPAP-Dokumentation und Nacharbeit, entsprechend rund AUD 20.000–60.000 Personalkosten p.a. in einem typischen mittelgroßen Kunststoffwerk mit PPAP-pflichtigen Kunden.

Kundenabwanderung durch nicht bestandene oder verspätete PPAPs

Logikbasiert: ca. 5–15 % des PPAP-pflichtigen Jahresumsatzes gefährdet; bei einem typischen Umsatz von AUD 4 Mio. mit Automotive- und ähnlichen Kunden entspricht das ca. AUD 200.000–600.000 potenziell verlorenem oder nicht gewonnenem Umsatz pro Jahr.

Capacity Loss from Manual Kanban Bottlenecks

AUD 20,000-100,000/year in lost capacity (2-5% of production value for mid-size firm, based on industry benchmarks for idle time)

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