Foundry & Forging calculator

Foundry Rework Rate Calculator

Calculate the rework rate for castings, forgings, molds, cores, heats, or machined cast products. Use it when defects require weld repair, grinding, straightening, heat-treat rework, dimensional correction, or retest.

What this calculator does

  • Calculate the rework rate for castings, forgings, molds, cores, heats, or machined cast products.
  • Use it when defects require weld repair, grinding, straightening, heat-treat rework, dimensional correction, or retest.
  • Measures rework burden in foundry or forge output.

Formula used

  • Foundry Rework Rate rate = reworked castings or forgings ÷ total inspected output × 100
  • Foundry Rework Rate gap to target = calculated rate - target maximum rework rate

Inputs explained

  • Reworked castings or forgings: Enter parts requiring rework, repair, retest, weld, grinding, straightening, or heat-treat rerun.
  • Total inspected output: Use matching castings, forgings, molds, cores, or lots inspected in the same period.
  • Target maximum rework rate: Use the quality target, customer limit, or internal continuous-improvement goal.

How to use the result

  • Use for quality reviews and tier boards.
  • This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.

Common questions

  • What information do I need before using the Foundry Rework Rate? Use reworked count, inspected output, and target rework rate for the same scope.
  • What does the result mean? It reports rework rate and gap to target.
  • When is the result only an estimate? This calculator is an estimating tool. Results can change with alloy chemistry, furnace practice, ladle losses, mold design, gating and riser layout, core condition, pattern allowance, die temperature, press condition, inspection criteria, rework rules, energy rates, labor standards, and actual shop performance. Validate safety-critical, metallurgical, tooling, press-capacity, and customer-spec decisions with qualified engineering, metallurgy, OEM data, and the applicable control plan.
  • What decision can I make from the result? Use it to prioritize defect reduction, schedule rework labor, and estimate quality cost.

Last reviewed 2026-05-12.