Graphite, Anode & Battery Materials Processing worked example

Rework Cost at 86% share of flagged material that is reworkable: a worked example in graphite, anode & battery materials processing

What does the result look like when share of flagged material that is reworkable reaches 86%? The full calculation is worked below with real intermediate numbers. Use it when deciding whether material outside PSD, tap density, coating loading, moisture, ash, impurity ppm, or blending limits should be reclassified, dried, recoated, blended, or scrapped.

The inputs for this scenario

  • Off-spec anode material flagged for rework: 600 kg (unchanged)
  • Rework processing cost per kg: 3.8 $ / kg (unchanged)
  • Share of flagged material that is reworkable: 86 % (raised for this scenario; the documented default is 75)
  • Fixed rework setup and changeover cost: 500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable rework cost = off-spec material for rework × rework cost per kg × reworkable material share) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,461 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 4.1 $ / piece for rework cost per kg reviewed.
  • At this operating point the engine returns 1,961 $ for variable rework cost.
  • At this operating point the engine returns 500 $ for fixed rework setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where share of flagged material that is reworkable sits at 75% and the headline result is 2,210 $, this scenario comes in 11.35% above the baseline at 2,461 $.
  • A figure at this level is achievable when share of flagged material that is reworkable is genuinely sustained, not just peaked for a shift. It assumes a single flat per-kg rework rate and one fixed setup; multi-step rework (re-mill then re-coat) or partial recovery within the reworkable share needs separate runs.

Results at a glance

  • Total rework cost: 2,461 $ (headline result)
  • Rework cost per kg reviewed: 4.1 $ / piece
  • Variable rework cost: 1,961 $
  • Fixed rework setup cost: 500 $

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.