Foundry & Forging calculator
Foundry Rework Rate Calculator
Check how many inspected castings or forgings needed rework. Enter distinct affected parts, the inspected lot size and your maximum rework rate.
What this calculator does
- Compare the fraction of distinct parts requiring rework with your maximum permitted rate.
Formula used
- Rework rate = reworked parts ÷ inspected parts × 100
- Margin below limit = maximum rework rate − actual rework rate
- Allowed whole parts = floor(inspected parts × maximum rate ÷ 100)
Inputs explained
- Parts Requiring Rework: Distinct inspected parts needing one or more rework operations.
- Total Inspected Parts: Complete inspected population for the same lot and checkpoint.
- Maximum Rework Rate: Your documented maximum permitted rework percentage.
How to use the result
- Best suited to lot quality review, rework limit tracking.
- This rate does not measure repair hours, scrap loss or final acceptance.
Current U.S. benchmarks
- The producer price index for steel mill products stands at 381.162 (BLS, Aug 2026), up 23.4% from a year earlier. Quotes priced off last quarter's material cost miss this move.
- The U.S. has 3,569 primary metal manufacturing establishments employing about 354,911 workers (Census County Business Patterns, 2023).
Common questions
- Does a twice-repaired casting count twice? No. This rate counts distinct parts requiring rework, so each casting counts once.
- Is rework the same as scrap? No. Rework describes additional work; scrap identifies parts rejected from usable output.
- Why round the allowed count down? A fraction of a part cannot be allowed. The whole count must remain within your percentage limit.
- What happens before any inspection? The rate and target margin remain blank because there is no inspected population.
Last reviewed 2026-10-06.