Aerospace & Defense Manufacturing worked example

Aerospace Rework Hour Capacity at 94% certified technician uptime: a worked example

Push certified technician uptime up to 94% and the picture changes. This example computes every intermediate figure at that operating point. a production manager needs to plan certified rework capacity for nonconforming flight or defense hardware

The inputs for this scenario

  • Rework hours per recovery cycle: 32 hr/cycle (unchanged)
  • Available recovery cycles: 12 cycles (unchanged)
  • Certified technician uptime: 94 % (raised for this scenario; the documented default is 82)
  • Accepted rework yield: 78 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross rework hour capacity = rework hours per cycle × available recovery cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 282 accepted rework hr for accepted aerospace rework capacity, the number this scenario is built around.
  • At this operating point the engine returns 384 accepted rework hr for gross rework hour capacity.
  • At this operating point the engine returns 23.04 accepted rework hr for technician downtime loss.
  • At this operating point the engine returns 79.41 accepted rework hr for rejected rework hour loss.

How this compares with the baseline

  • Against the tool's baseline example, where certified technician uptime sits at 82% and the headline result is 246 accepted rework hr, this scenario comes in 14.63% above the baseline at 282 accepted rework hr.
  • It computes accepted rework capacity by derating gross rework hours for certified-technician uptime and the yield of rework that actually passes re-inspection. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Accepted aerospace rework capacity: 282 accepted rework hr (headline result)
  • Gross rework hour capacity: 384 accepted rework hr
  • Technician downtime loss: 23.04 accepted rework hr
  • Rejected rework hour loss: 79.41 accepted rework hr

Run it with your numbers

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

Last reviewed 2026-05-12.