Adhesives, Sealants & Industrial Bonding worked example

Bond Rework Exposure at 50% expected rework exposure: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected rework exposure to 50%, then walk the calculation through step by step. Estimate rework cost exposure for bonded assemblies from rework quantity, repair cost, expected recovery share, and setup charge.

The inputs for this scenario

  • Assemblies needing bond rework: 16 assemblies (held at the documented default)
  • Repair cost per assembly: 95 $ / assembly (held at the documented default)
  • Expected rework exposure: 50 % (the input this scenario stresses; the baseline uses 70)
  • Teardown and setup charge: 240 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Expected repair exposure = assemblies needing rework × repair cost per assembly × expected rework exposure.
  • Bond rework exposure works out to 1,000 $ rework at these inputs, and this is the headline figure for the scenario.
  • Repair cost per assembly works out to 62.5 $ / assembly at these inputs.
  • Expected repair exposure works out to 760 $ rework at these inputs.
  • Teardown and setup charge works out to 240 $ at these inputs.

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 23.31% below the baseline at 1,000 $ rework.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected rework exposure, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The expected exposure percentage is an estimate of how many flagged assemblies truly need rework; if your inspection has high false-call or escape rates, the weighted figure will be off and you should validate it against actual teardown results.

Results at a glance

  • Bond rework exposure: 1,000 $ rework (headline result)
  • Repair cost per assembly: 62.5 $ / assembly
  • Expected repair exposure: 760 $ rework
  • Teardown and setup charge: 240 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Bond Rework Exposure calculator, set expected rework exposure to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.