Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Stack Rework Cost at 69% share of stack touched: a worked example

What does the result look like when share of stack touched reaches 69%? The full calculation is worked below with real intermediate numbers. Use it when a quality engineer or production manager is sizing the dollar drag of stack rework after a leak-test or voltage failure spike and needs an honest number for finance and the corrective action plan.

The inputs for this scenario

  • Stacks reworked in the period: 18 stacks (unchanged)
  • Rework cost per stack: 850 $ / stack (unchanged)
  • Share of stack touched: 69 % (raised for this scenario; the documented default is 60)
  • Fixed rework setup or MRB cost: 1,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable stack rework cost = stacks reworked × rework cost per stack × share of stack touched) to the inputs above produces each figure below.
  • At this operating point the engine returns 11,757 $ for total stack rework cost, the number this scenario is built around.
  • At this operating point the engine returns 653 $ / piece for rework cost per touched stack.
  • At this operating point the engine returns 10,557 $ for variable stack rework cost.
  • At this operating point the engine returns 1,200 $ for fixed rework setup or mrb cost.

How this compares with the baseline

  • Against the tool's baseline example, where share of stack touched sits at 60% and the headline result is 10,380 $, this scenario comes in 13.27% above the baseline at 11,757 $.
  • A figure at this level is achievable when share of stack touched is genuinely sustained, not just peaked for a shift. It uses one average cost per stack and one share-touched figure; a mix of light teardown and full rebuilds in the same period will blur the true cost unless segmented.

Results at a glance

  • Total stack rework cost: 11,757 $ (headline result)
  • Rework cost per touched stack: 653 $ / piece
  • Variable stack rework cost: 10,557 $
  • Fixed rework setup or MRB cost: 1,200 $

Run it with your numbers

  • Every input above is editable in the live Stack Rework Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.