Manufacturing Scrap Rate by Process
Process-specific scrap benchmarks, common defect types, and reduction guides — from stamping and welding to injection molding and assembly.
Primary Processes
- Metal StampingAvg. scrap rate: 4.5% · Top quartile: 1.5%Metal stamping uses custom dies mounted in a press to cut, bend, and form flat metal sheets into fin…
- Injection MoldingAvg. scrap rate: 5% · Top quartile: 1.5%Injection molding forces molten plastic into a mold cavity under high pressure, producing complex pa…
- Welding & JoiningAvg. scrap rate: 4.8% · Top quartile: 1.5%Welding joins metal components using heat or pressure. Rework rates are higher than scrap rates beca…
- Manual & Semi-Automated AssemblyAvg. scrap rate: 3.2% · Top quartile: 0.8%Assembly combines manufactured components into finished products. Scrap and rework in assembly is dr…
- Filling & Packaging LinesAvg. scrap rate: 6% · Top quartile: 2.5%Filling and packaging lines apply packaging to food, beverage, or consumer products at high speed. S…