Microgrid & Distributed Energy Equipment worked example

Rework Cost at 92% share of build affected: a worked example in microgrid & distributed energy equipment

What does the result look like when share of build affected reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when rework on microgrid and distributed energy assemblies needs a defensible cost for a quality review or quote.

The inputs for this scenario

  • Units needing rework: 100 units (unchanged)
  • Rework cost per unit: 45 $ / unit (unchanged)
  • Share of build affected: 92 % (raised for this scenario; the documented default is 80)
  • Fixed containment cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable rework cost = units needing rework × rework cost per unit × share of build affected) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for rework cost per unit.
  • At this operating point the engine returns 4,140 $ for variable rework cost.
  • At this operating point the engine returns 250 $ for fixed containment cost.

How this compares with the baseline

  • Against the tool's baseline example, where share of build affected sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when share of build affected is genuinely sustained, not just peaked for a shift. It assumes a uniform per-unit rework cost; in practice rework hours vary by defect and by how deep into assembly the unit was when caught.

Results at a glance

  • Total rework cost: 4,390 $ (headline result)
  • Rework cost per unit: 43.9 $ / piece
  • Variable rework cost: 4,140 $
  • Fixed containment cost: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.