RedHub AI
How the gate works
How the Cost-of-Poor-Quality gate works
This tool grades a manufacturing cell's true cost of poor quality against its own revenue. It scores 5 weighted controls into a 0–100 number — then a gate that can only make the verdict worse.
The 5 weighted controls
A single cost stream that is both 60%+ of the cell's total COPQ dollars and over a $25,000 floor forces BLEEDING regardless of the ratio-only score - a concentrated leak in one stream is a different problem than the same dollars spread thin, and a ratio alone would hide it.
Why: The five weighted streams score 25 - COST DRAG on their own math, since no stream is a runaway on its own weight. But Warranty/returns is $52,000, 75% of this cell's $69,000 total COPQ (7.7% of $900,000 revenue) and clears the $25,000 concentration floor - the dominance gate forces BLEEDING regardless of the ratio.
A high score didn’t save it. The score is context; the gate is the answer — and it names the one thing to fix first. Your own cost inputs, computed offline. Not an audited financial figure or an industry benchmark.