Electronics Repair, Refurbishment & Depot Operations worked example

BGA Reball/Reflow Labor Cost at 58% boards requiring reball and reflow: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop boards requiring reball and reflow to 58%, then walk the calculation through step by step. Estimate labor cost for BGA reball, reflow, solder-joint repair, X-ray review, stencil setup, and post-rework testing in a depot repair workflow.

The inputs for this scenario

  • Boards routed to reball/reflow: 100 boards (held at the documented default)
  • Labor cost per reball/reflow board: 45 $ / board (held at the documented default)
  • Boards requiring reball/reflow: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed fixture, stencil, or X-ray cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable reball/reflow labor cost = boards routed to reball/reflow × labor cost per reball/reflow board × boards requiring reball/reflow.
  • Total BGA reball/reflow labor cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Reball/reflow labor cost per board works out to 28.6 $ / piece at these inputs.
  • Variable reball/reflow labor cost works out to 2,610 $ at these inputs.
  • Fixed fixture, stencil, or X-ray cost works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where boards requiring reball and reflow sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to boards requiring reball and reflow, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a single labor rate and reflow profile; complex multi-BGA boards, lead-free versus leaded reballs, and first-pass yield loss can each push real cost well above the average.

Results at a glance

  • Total BGA reball/reflow labor cost: 2,860 $ (headline result)
  • Reball/reflow labor cost per board: 28.6 $ / piece
  • Variable reball/reflow labor cost: 2,610 $
  • Fixed fixture, stencil, or X-ray cost: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live BGA Reball/Reflow Labor Cost calculator, set boards requiring reball and reflow to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.