Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Stack Rework Cost at 43% share of stack touched: a worked example

Suppose share of stack touched falls to 43%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate per-stack rework cost from the count of stacks reworked, average rework cost per stack (labor plus replaced MEAs, gaskets, plates), the share of the stack actually touched, and a fixed rework setup or MRB cost.

The inputs for this scenario

  • Stacks reworked in the period: 18 stacks (held at the documented default)
  • Rework cost per stack: 850 $ / stack (held at the documented default)
  • Share of stack touched: 43 % (the input this scenario stresses; the baseline uses 60)
  • Fixed rework setup or MRB cost: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable stack rework cost = stacks reworked × rework cost per stack × share of stack touched.
  • Total stack rework cost works out to 7,779 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per touched stack works out to 432 $ / piece at these inputs.
  • Variable stack rework cost works out to 6,579 $ at these inputs.
  • Fixed rework setup or MRB cost works out to 1,200 $ at these inputs.

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 25.06% below the baseline at 7,779 $.
  • It computes total stack rework cost as variable rework (stacks reworked times cost per stack times share touched) plus a fixed setup or MRB cost. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total stack rework cost: 7,779 $ (headline result)
  • Rework cost per touched stack: 432 $ / piece
  • Variable stack rework cost: 6,579 $
  • Fixed rework setup or MRB cost: 1,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Stack Rework Cost calculator, set share of stack touched to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.