The model is fixed; only the cut-off moves. The costs are stated assumptions, and
every row is arithmetic from them.
20,000 machine-days scored per month, 200 true failures -> 1.0% positive.
Missed failure: unplanned outage, £6,000. Inspection: £150.
Doing nothing at all: 200 x £6,000 = £1,200,000.
thresh TP FN FP inspections FN cost inspect cost total
------ ---- ---- ----- ----------- --------- ------------ ----------
0.10 180 20 2,400 2,580 £120,000 £387,000 £507,000
0.30 150 50 700 850 £300,000 £127,500 £427,500
0.50 120 80 240 360 £480,000 £54,000 £534,000
0.70 80 120 60 140 £720,000 £21,000 £741,000
precision and F1 at each threshold:
0.10 p = 180/2,580 = 0.070 r = 0.90 F1 = 0.130
0.30 p = 150/ 850 = 0.176 r = 0.75 F1 = 0.285
0.50 p = 120/ 360 = 0.333 r = 0.60 F1 = 0.426
0.70 p = 80/ 140 = 0.571 r = 0.40 F1 = 0.471
The cost column and the F1 column point in opposite directions. Cost is minimised
at 0.30, where precision is 17.6% — five inspections per genuine fault, which
reads like a bad model. F1 is maximised at 0.70, which costs £741,000, or £313,500
more than the cost-optimal choice. Selecting a threshold by F1 here is a
£313,500 decision made by a metric that was never told what anything costs.
The reason is structural rather than accidental. F1 is the harmonic mean of
precision and recall, which weights them equally, and this problem weights them at
forty to one — a missed failure costs £6,000 against £150 for an inspection.
Any single metric that does not contain the cost ratio will pick the wrong point
whenever that ratio is far from one.
The no-model baseline belongs in the table. £1,200,000 of avoidable outage is what
the business bears today, so the 0.30 threshold saves £772,500 a month, and that
figure is what justifies the project. A precision of 17.6% quoted without it
sounds like failure.
Two refinements worth volunteering. Inspection capacity is usually a hard
constraint, so if the team can only handle 400 inspections a month the 0.30 row is
unavailable regardless of its cost and you are choosing among feasible thresholds
— which is the fixed-budget framing. And the cost per inspection is not constant:
send too many and the team starts skipping them, so the real curve bends in a way
no static table shows and only an operating review will surface.