Cathode Active Material & Precursor Manufacturing worked example

Rework Cost at 92% mass requiring rework: a worked example in cathode active material & precursor manufacturing

What does the result look like when mass requiring rework reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when rework cost in cathode active material and precursor manufacturing is being put through a cathode active material and precursor manufacturing weighted-cost review.

The inputs for this scenario

  • Reworkable CAM or precursor mass: 100 kg (unchanged)
  • Variable rework cost: 45 $ / kg (unchanged)
  • Mass requiring rework: 92 % (raised for this scenario; the documented default is 80)
  • Fixed rework setup cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable rework cost subtotal = reworkable CAM or precursor mass × variable rework cost × mass requiring rework) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for total cam rework cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for effective rework cost per kg held.
  • At this operating point the engine returns 4,140 $ for variable rework cost subtotal.
  • At this operating point the engine returns 250 $ for fixed rework setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where mass requiring rework sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when mass requiring rework is genuinely sustained, not just peaked for a shift. It assumes a single rework pass at a known cost; multi-pass rework, yield loss during rework, and the risk that reworked material fails a second time are not modeled and can materially raise the true cost.

Results at a glance

  • Total CAM rework cost: 4,390 $ (headline result)
  • Effective rework cost per kg held: 43.9 $ / piece
  • Variable rework cost subtotal: 4,140 $
  • Fixed rework setup cost: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.