EV Charging Infrastructure Manufacturing worked example

Rework Cost at 110% rework occurrence share assigned: a worked example in ev charging infrastructure manufacturing

This scenario runs the rework cost calculation on the strong side: 110% rework occurrence share assigned, with every other input held at its documented default. a quality manager needs to quantify charger rework impact from a defect or build issue

The inputs for this scenario

  • Chargers or modules requiring rework: 64 units (unchanged)
  • Rework labor and material cost per unit: 145 $ / unit (unchanged)
  • Rework occurrence share assigned: 110 % (raised for this scenario; the documented default is 100)
  • Fixed engineering and containment adders: 2,400 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable rework cost = reworked units × rework cost per unit × assigned occurrence share) to the inputs above produces each figure below.
  • At this operating point the engine returns 12,608 $ for total ev charger rework cost, the number this scenario is built around.
  • At this operating point the engine returns 197 $ / unit for rework cost per affected unit.
  • At this operating point the engine returns 10,208 $ for variable rework cost.
  • At this operating point the engine returns 2,400 $ for engineering and containment adders.

How this compares with the baseline

  • Against the tool's baseline example, where rework occurrence share assigned sits at 100% and the headline result is 11,680 $, this scenario comes in 7.95% above the baseline at 12,608 $.
  • Use it when scoping the cost-of-poor-quality for a specific defect mode, building a rework reserve for a charger build, or quantifying the savings case for a corrective action. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total EV charger rework cost: 12,608 $ (headline result)
  • Rework cost per affected unit: 197 $ / unit
  • Variable rework cost: 10,208 $
  • Engineering and containment adders: 2,400 $

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.