How do you calculate the cost of a rush order?

Multiply affected units by the incremental cost per unit and the share of scope you're charging for, then add the fixed coordination cost. For 260 units at $18.25 premium each, 100% charged, plus $2,400 fixed, total rush cost is $7,145.

What is a fair rush order surcharge?

Charge at least your true added cost. In the worked case that's $7,145 across 260 units, or about $27.48 per piece all-in — well above the $18.25 variable premium because the $2,400 fixed coordination cost spreads across the run.

Why include a fixed expedite cost separately?

Because coordination effort doesn't scale with quantity. A 50-unit rush and a 260-unit rush can both eat the same $2,400 of planner time, supplier expedite fees, and freight setup, so on small rushes the fixed cost dominates the per-piece premium.

What does the 'rush scope charged to customer' percentage do?

It lets you absorb part of the premium as goodwill. At 100% the customer covers the full variable cost; drop it to 70% and you eat 30% of the per-unit expedite cost while still recovering the fixed coordination charge.

Should rush cost include the jobs I delay?

This tool prices only the direct expedite cost. If pulling the rush forward pushes other promised orders late, add their late penalties or lost-margin separately — on a full shop that indirect hit can exceed the $7,145 direct cost shown here.

Contract Manufacturing, Job Shop Quoting & Make-to-Order calculator

Rush Order Cost Calculator

Rush order cost is the true added cost of pulling a make-to-order job forward — the per-unit premium for overtime, expedited material, and resequencing, plus the fixed coordination overhead an expedite triggers. Job shop estimators and customer service teams use it to set a defensible rush surcharge instead of guessing. The trap is treating a rush as just overtime; the fixed coordination cost (planner time, supplier expedite fees, freight upgrades) is often the part that quietly erodes margin. This calculator separates variable from fixed so you can quote a premium that actually covers what the rush costs you.

What this calculator does

Estimate extra cost created by rush or expedited customer orders.
deciding whether the expedite fee covers the real cost of jumping the schedule
It computes total rush order cost as the per-unit incremental premium times units times the share you charge for, plus a fixed expedite coordination cost.

Formula used

Variable rush order cost = rush-order units affected × incremental rush cost per unit × rush scope charged to customer
Total rush order cost = variable rush order cost + fixed expedite coordination cost

Inputs explained

Rush-order units affected:
Incremental rush cost per unit:
Rush scope charged to customer:
Fixed expedite coordination cost:

How to use the result

Use it when a customer asks for an expedited delivery and you need a surcharge that covers overtime, premium freight, and the disruption to scheduled work.
It prices the direct cost of one rush in isolation; it does not capture the opportunity cost of the standard jobs you bump, which can dwarf the direct premium on a loaded shop.

Current U.S. benchmarks

The U.S. prime lending rate is 6.75% (Federal Reserve via FRED, 2026-07-02). Payback and financing math should start from today's rate, not a remembered one.

Common questions

How do you calculate the cost of a rush order? Multiply affected units by the incremental cost per unit and the share of scope you're charging for, then add the fixed coordination cost. For 260 units at $18.25 premium each, 100% charged, plus $2,400 fixed, total rush cost is $7,145.
What is a fair rush order surcharge? Charge at least your true added cost. In the worked case that's $7,145 across 260 units, or about $27.48 per piece all-in — well above the $18.25 variable premium because the $2,400 fixed coordination cost spreads across the run.
Why include a fixed expedite cost separately? Because coordination effort doesn't scale with quantity. A 50-unit rush and a 260-unit rush can both eat the same $2,400 of planner time, supplier expedite fees, and freight setup, so on small rushes the fixed cost dominates the per-piece premium.
What does the 'rush scope charged to customer' percentage do? It lets you absorb part of the premium as goodwill. At 100% the customer covers the full variable cost; drop it to 70% and you eat 30% of the per-unit expedite cost while still recovering the fixed coordination charge.
Should rush cost include the jobs I delay? This tool prices only the direct expedite cost. If pulling the rush forward pushes other promised orders late, add their late penalties or lost-margin separately — on a full shop that indirect hit can exceed the $7,145 direct cost shown here.

Last reviewed 2026-05-12.