Mattress, Bedding & Foam Product Assembly worked example

Defect/Rework Cost at 22% throughput loss factor: a worked example

This worked example runs the defect/rework cost numbers for a tougher week than the baseline: 22% throughput loss factor instead of the typical 30%. Calculate the total cost of mattress defects and rework including labor to repair, replacement materials, and lost throughput during the rework cycle.

The inputs for this scenario

  • Defective units requiring rework: 12 mattresses (held at the documented default)
  • Average rework cost per unit: 35 $ / mattress (held at the documented default)
  • Throughput loss factor: 22 % (the input this scenario stresses; the baseline uses 30)
  • Fixed quality overhead: 200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Direct rework cost = defective units × average rework cost per unit.
  • Weighted cost works out to 292 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 24.37 $ / piece at these inputs.
  • Captured value works out to 92.4 $ at these inputs.
  • Fixed adjustment works out to 200 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where throughput loss factor sits at 30% and the headline result is 326 $, this scenario comes in 10.31% below the baseline at 292 $.
  • Use it after a shift or audit to size the cost of a defect category, or to justify a fixture, training, or inspection investment. 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

  • Weighted cost: 292 $ (headline result)
  • Per piece value: 24.37 $ / piece
  • Captured value: 92.4 $
  • Fixed adjustment: 200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Defect/Rework Cost calculator, set throughput loss factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.