In cable manufacturing, scrap rate and defect frequency are not just quality metrics — they are direct indicators of process maturity, equipment–process matching, and factory management discipline. Yet most cable plants lack a realistic benchmark. Targets are often set based on experience, supplier promises, or internal history rather than industry-wide reference points.

This benchmark report consolidates typical scrap and defect rate ranges observed across different cable types and key manufacturing processes, helping manufacturers evaluate whether their current performance is competitive, acceptable, or structurally inefficient.

This report focuses on typical operational ranges, not theoretical best cases.

1. How to Read This Benchmark Report

Before diving into numbers, three clarifications are critical:

1. Scrap rate includes startup scrap, changeover loss, in-process defects, and rejected finished lengths.

2. Defect rate refers to defects detected by online testing (spark test, diameter, concentricity) or offline inspection.

3. Values shown represent stable production after ramp-up, not commissioning periods.

Actual performance depends on equipment condition, operator skill, material consistency, and production discipline.

2. Typical Scrap Rates by Cable Type

Building Wire (PVC / PE Insulation)

• Typical scrap rate: 1.5% – 3.0%

• Main contributors:

  • Startup instability

  • Diameter fluctuation

  • Color change purge loss

Well-controlled lines with standardized setups can reach the lower end consistently.

Power Cables (LV / MV)

• Typical scrap rate: 2.5% – 5.0%

• Main contributors:

  • Concentricity deviation

  • Insulation eccentricity during acceleration

  • Jointing and take-up transitions

Scrap increases significantly with cable size variation and frequent order changes.

Control & Instrumentation Cables

• Typical scrap rate: 3.0% – 6.0%

• Main contributors:

  • Pair imbalance

  • Lay length variation

  • Shield overlap inconsistency

Process synchronization between twisting and extrusion is the dominant factor.

Data & Communication Cables

• Typical scrap rate: 4.0% – 8.0%

• Main contributors:

  • Spark test failures

  • Pair geometry deviation

  • Foaming instability

High-speed lines amplify small process errors into measurable scrap.

Flexible / Silicone / Special Cables

• Typical scrap rate: 5.0% – 10.0%

• Main contributors:

  • Material sensitivity

  • Temperature window instability

  • Adhesion and surface defects

Material behavior dominates over machine capability in this category.

3. Scrap Rate Benchmarks by Process Stage

Conductor Drawing

• Typical scrap rate: 0.5% – 1.5%

• Key loss sources:

  • Wire breakage

  • Surface scoring

Stranding / Twisting

• Typical scrap rate: 1.0% – 3.5%

• Key loss sources:

  • Lay instability

  • Bird-caging

  • Tension mismatch

Insulation Extrusion

• Typical scrap rate: 2.0% – 6.0%

• Key loss sources:

  • Diameter out-of-tolerance

  • Bubbles and pinholes

  • Startup thermal imbalance

Jacketing

• Typical scrap rate: 1.5% – 4.0%

• Key loss sources:

  • Ovality

  • Surface defects

  • Cooling deformation

4. Typical Defect Rate Ranges (Online Detection)

Defect Type

Factories exceeding these ranges consistently should investigate structural causes rather than isolated incidents.

5. What Separates Low-Scrap and High-Scrap Factories

Across cable plants, performance differences are rarely explained by machine brand alone.

Low-scrap factories typically show:

• Narrow, documented process windows

• Stable material suppliers

• Operator-specific accountability

• Preventive maintenance tied to defect trends

High-scrap factories often show:

• Parameter drift between shifts

• Reactive troubleshooting culture

• Overreliance on speed to offset loss

6. Interpreting Your Own Numbers Correctly

A scrap rate above benchmark does not automatically indicate poor management. It may reflect:

• High product mix complexity

• Frequent order changeovers

• R&D or customized production focus

The real risk lies in unknown or untracked scrap drivers.

7. Using Benchmarks to Drive Real Improvement

Benchmarks are not targets; they are reference points.

Effective use includes:

• Segmenting scrap by product and process

• Linking defect data to specific equipment zones

• Prioritizing stability before speed

Incremental reduction of 0.5% scrap often delivers greater profit impact than large capital investment.

Final Perspective

In cable manufacturing, scrap is not an unavoidable cost — it is a signal. Factories that treat scrap data as operational feedback rather than accounting loss consistently outperform peers.

At DX Cable Technology, we support manufacturers in benchmarking real production performance, identifying structural loss drivers, and aligning equipment capability with process reality, enabling sustainable improvement rather than temporary fixes.