Electronics Manufacturing worked example

Electronics Rework Cost with assemblies requiring rework of 220 assemblies: a worked example

What does the result look like when assemblies requiring rework reaches 220 assemblies? The full calculation is worked below with real intermediate numbers. a quality or operations team needs to quantify the cost impact of rework

The inputs for this scenario

  • Assemblies requiring rework: 220 assemblies (raised for this scenario; the documented default is 86)
  • Variable rework cost: 9.5 $ / assembly (unchanged)
  • Rework labor and setup cost: 520 $ (unchanged)
  • Retest, inspection, and overhead cost: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total electronics rework cost = assemblies requiring rework × variable rework cost + labor/setup + overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,790 $ for total electronics rework cost, the number this scenario is built around.
  • At this operating point the engine returns 12.68 $ / assembly for rework cost per assembly.
  • At this operating point the engine returns 2,090 $ for variable rework material cost.
  • At this operating point the engine returns 700 $ for rework labor, retest, and overhead adders.

How this compares with the baseline

  • Against the tool's baseline example, where assemblies requiring rework sits at 86 assemblies and the headline result is 1,517 $, this scenario comes in 83.92% above the baseline at 2,790 $.
  • A figure at this level is achievable when assemblies requiring rework is genuinely sustained, not just peaked for a shift. It assumes the assemblies are actually salvageable; if rework damages pads or lifts traces and the board later fails, the real cost includes the eventual scrap plus the wasted rework labor, which this model does not predict.

Results at a glance

  • Total electronics rework cost: 2,790 $ (headline result)
  • Rework cost per assembly: 12.68 $ / assembly
  • Variable rework material cost: 2,090 $
  • Rework labor, retest, and overhead adders: 700 $

Run it with your numbers

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

Last reviewed 2026-05-12.