Mass Finishing, Deburring & Polishing worked example

Rework Reduction Savings at 65% cell yield efficiency: a worked example

This worked example runs the rework reduction savings numbers for a tougher week than the baseline: 65% cell yield efficiency instead of the typical 90%. Calculate rework reduction savings for mass finishing, deburring & polishing planning, quoting, troubleshooting, capacity review, or process improvement.

The inputs for this scenario

  • Good parts after rework reduction: 1,200 units (held at the documented default)
  • Finishing cell runtime: 8 hr (held at the documented default)
  • Cell yield efficiency: 65 % (the input this scenario stresses; the baseline uses 90)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw rework reduction savings = completed output รท runtime.
  • Effective throughput works out to 97.5 units at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 150 units at these inputs.
  • Efficiency works out to 65 % at these inputs.
  • Runtime works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where cell yield efficiency sits at 90% and the headline result is 135 units, this scenario comes in 27.78% below the baseline at 97.5 units.
  • Use it to baseline a finishing line before a process change and to measure the throughput recovered when rework drops. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Effective throughput: 97.5 units (headline result)
  • Raw throughput: 150 units
  • Efficiency: 65 %
  • Runtime: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Reduction Savings calculator, set cell yield efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.