How do you calculate total rework cost?

Multiply reworked assemblies by per-unit rework cost by the capture factor, then add fixed costs. Here 32 x 4.75 x 100% = 152, plus a 200 fixed cost = 352 total.

What is the cost capture factor for?

It is the share of rework cost you actually count — useful when some rework is absorbed by a supplier or warranty. At 100% you count all of it, so the full 152 variable cost flows through.

Should I include rework in my cost of quality?

Yes — rework is an internal failure cost. Tracking the 352 total monthly lets you compare it against prevention spend like a better crimp die or in-process leak test.

Rework cost vs. scrap cost — which is cheaper?

Rework keeps the material but adds labor and re-test time; scrap loses the material but frees the line faster. Compare this total against the scrap-and-rebuild cost per assembly to decide.

Why add a fixed disposition cost?

Some rework triggers one-off charges — a re-inspection setup, an MRB review, or a re-test fixture — that do not scale per unit. The 200 fixed term in the example captures exactly that.

Does this include the cost of lost capacity?

No. The 352 figure is direct rework dollars only. If the crimper is your bottleneck, the throughput lost while reworking those 32 assemblies can exceed the rework labor itself.

Hose, Tubing & Fluid Conveyance Products calculator

Rework Cost Calculator

Rework cost quantifies what it really costs to salvage hose and tubing assemblies that fail inspection — re-crimping, re-cutting, re-testing, and the disposition paperwork around them. Quality and cost accountants in fluid-conveyance plants use it to put a dollar figure on a defect category so it can be compared against the price of preventing it. The capture factor lets you count only the portion of rework you actually absorb, and the fixed term captures one-off disposition or re-inspection charges. It turns a vague 'we have a rework problem' into a number that justifies a fixture, a die change, or a supplier conversation.

What this calculator does

Estimate the cost of reworking rejected hose or tubing assemblies from rework quantity, rework cost rate, capture factor, and fixed disposition or re-inspection cost.
Use it when calculating the cost impact of hose assembly rework from failed crimp dimensions, leak test rejects, wrong fitting orientation, or incorrect cut length.
It multiplies reworked assemblies by per-unit cost and the capture factor for the variable portion, then adds a fixed disposition or re-inspection cost.

Formula used

Variable rework cost = reworked assemblies x rework cost per assembly x capture factor
Total rework cost = variable rework cost + fixed disposition or re-inspection cost

Inputs explained

Hose assemblies requiring rework:
Rework labor & material cost per assembly:
Cost capture factor (share of rework counted):
Fixed disposition or re-inspection cost:

How to use the result

Use it to cost out a defect category for the month, to build a cost-of-quality case, or to compare rework against scrap-and-rebuild.
It captures direct rework dollars only — it does not value the lost throughput, late shipments, or customer goodwill that often dwarf the rework labor itself.

Current U.S. benchmarks

The U.S. has 11,391 plastics and rubber products establishments employing about 815,988 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate total rework cost? Multiply reworked assemblies by per-unit rework cost by the capture factor, then add fixed costs. Here 32 x 4.75 x 100% = 152, plus a 200 fixed cost = 352 total.
What is the cost capture factor for? It is the share of rework cost you actually count — useful when some rework is absorbed by a supplier or warranty. At 100% you count all of it, so the full 152 variable cost flows through.
Should I include rework in my cost of quality? Yes — rework is an internal failure cost. Tracking the 352 total monthly lets you compare it against prevention spend like a better crimp die or in-process leak test.
Rework cost vs. scrap cost — which is cheaper? Rework keeps the material but adds labor and re-test time; scrap loses the material but frees the line faster. Compare this total against the scrap-and-rebuild cost per assembly to decide.
Why add a fixed disposition cost? Some rework triggers one-off charges — a re-inspection setup, an MRB review, or a re-test fixture — that do not scale per unit. The 200 fixed term in the example captures exactly that.

Last reviewed 2026-05-12.