The residual fiber length in a molded part is one of the most important microstructural properties of discontinuous fiber‐reinforced composites. While there have been several research studies characterizing the process‐induced fiber length reduction, the measurement procedures vary substantially, calling into question the comparability of reported results. This article introduces a newly developed measurement procedure that aims to provide accurate, repeatable, robust, and time efficient fiber length analyses. A comprehensive study of measurement techniques was performed comparing commercially available systems and the conventional approach of measuring the fiber length manually. The results emphasize the need for a standardized procedure to characterize the fiber length distribution and the risk of generating inadequate results through improper sample preparation. The developed measurement technique was tested and compared for an experimental study of fiber breakage in injection molding. For a simple plaque geometry, the residual fiber length along the flow path was obtained for a long glass fiber‐reinforced polypropylene at 30 and 40%wt for varying process conditions. The new measurement technique showed accurate and repeatable results. The results of the injection molding study showed that screw speed and back pressure are important factors that drive fiber breakage. An increase in back pressure from 13 to 50 bar and screw speed from 27 to 35 rpm reduces the weight‐average fiber length by 37.5%. POLYM. COMPOS., 39:4058–4070, 2018. © 2017 Society of Plastics Engineers