The PAF (Prevention–Appraisal–Failure) model, built for manufacturing quality managers. Track every dollar of quality cost, benchmark against revenue, and present compelling business cases to leadership.
| Category | Cost Element | Q1 Actual | Q2 Actual | Q3 Actual | Q4 Actual | FY Total | % Revenue |
|---|---|---|---|---|---|---|---|
| PREVENTION COSTS | |||||||
| Prevention | Quality Training Programs | $4,200 | $3,800 | $4,500 | $4,800 | $17,300 | 0.41% |
| Prevention | SPC / Process Control Systems | $3,100 | $3,100 | $3,100 | $3,100 | $12,400 | 0.30% |
| Prevention | Supplier Development & Audits | $2,800 | $2,400 | $2,900 | $3,200 | $11,300 | 0.27% |
| Prevention | Preventive Maintenance Program | $5,400 | $5,100 | $5,600 | $5,900 | $22,000 | 0.53% |
| Prevention Subtotal | $15,500 | $14,400 | $16,100 | $17,000 | $63,000 | 1.51% | |
| APPRAISAL COSTS | |||||||
| Appraisal | Laboratory Testing & Analysis | $8,200 | $7,900 | $8,400 | $8,100 | $32,600 | 0.78% |
| Appraisal | In-Process Quality Inspections | $6,400 | $6,200 | $6,600 | $6,500 | $25,700 | 0.62% |
| Appraisal | Finished Product Testing | $4,100 | $3,900 | $4,300 | $4,200 | $16,500 | 0.40% |
| Appraisal Subtotal | $18,700 | $18,000 | $19,300 | $18,800 | $74,800 | 1.80% | |
| FAILURE COSTS | |||||||
| Int. Failure | Rework & Reprocessing | $3,100 | $2,400 | $1,800 | $1,200 | $8,500 | 0.20% |
| Int. Failure | Blocked Stock / Holds | $1,800 | $900 | $600 | $0 | $3,300 | 0.08% |
| Ext. Failure | Customer Complaints (COPQ) | $1,200 | $900 | $600 | $400 | $3,100 | 0.07% |
| TOTAL COST OF QUALITY | $39,300 | $36,600 | $38,400 | $37,400 | $151,700 | 3.64% | |