To calculate your plywood waste percentage over a month, track the total square footage purchased versus the actual square footage used in projects, then use the formula:

Steps to Track and Calculate Waste:
  • Establish a Tracking System: Keep a logbook or spreadsheet in the shop. Record every sheet of plywood brought in (
     sq ft).
  • Log Usage & Waste: For every project, record the total square footage of parts used in the final product. Measure and record the square footage of leftover offcuts and unused damaged material.
  • Calculate Weekly Totals: At the end of each week, sum your total purchased area, used area, and waste area.
  • Monthly Calculation: At the end of the month, apply the formula.
  • Analyze Causes: Note if waste is due to poor layout planning, small offcuts, or grain matching (usually 10-15%).
  • Use Optimization Tools: Utilize free software like Cutlist Optimizer or CutlistEVO to estimate waste before cutting and compare it to your actual waste to improve efficienc


    Typical Waste Percentages: Varies by volume, materials and typical dimensions.
  • Standard Projects: 15–20%.
  • Complex/Detailed Projects: 20–30%.

In some cases you may prefer to charge based on total sheets used. Keep in mind this requires additional labor time to determine this value or the actual building of your crates first. This reduces your ROI (return on investment) and can actually reduce your profits over time.

Full Sheet Costing and Selling: Plywood and Foam