Adhesives, Sealants & Industrial Bonding worked example

Bond Rework Exposure at 81% expected rework exposure: a worked example

This scenario runs the bond rework exposure calculation on the strong side: 81% expected rework exposure, with every other input held at its documented default. a production manager needs to estimate cost exposure from bonding defects found after assembly

The inputs for this scenario

  • Assemblies needing bond rework: 16 assemblies (unchanged)
  • Repair cost per assembly: 95 $ / assembly (unchanged)
  • Expected rework exposure: 81 % (raised for this scenario; the documented default is 70)
  • Teardown and setup charge: 240 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Expected repair exposure = assemblies needing rework × repair cost per assembly × expected rework exposure) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,471 $ rework for bond rework exposure, the number this scenario is built around.
  • At this operating point the engine returns 91.95 $ / assembly for repair cost per assembly.
  • At this operating point the engine returns 1,231 $ rework for expected repair exposure.
  • At this operating point the engine returns 240 $ for teardown and setup charge.

How this compares with the baseline

  • Against the tool's baseline example, where expected rework exposure sits at 70% and the headline result is 1,304 $ rework, this scenario comes in 12.82% above the baseline at 1,471 $ rework.
  • Use it during containment of a bonding nonconformance, when quoting warranty rework, or when comparing rework versus scrap on a flagged lot. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Bond rework exposure: 1,471 $ rework (headline result)
  • Repair cost per assembly: 91.95 $ / assembly
  • Expected repair exposure: 1,231 $ rework
  • Teardown and setup charge: 240 $

Run it with your numbers

  • Every input above is editable in the live Bond Rework Exposure calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.