Microgrid & Distributed Energy Equipment worked example

Rework Cost at 58% share of build affected: a worked example in microgrid & distributed energy equipment

Here is what the math looks like when conditions slip. We hold every other input steady and drop share of build affected to 58%, then walk the calculation through step by step. Estimate the rework cost on microgrid and distributed energy assemblies, so quality and operations teams can size the hit, compare scenarios, or decide whether it is material to the build budget or quote.

The inputs for this scenario

  • Units needing rework: 100 units (held at the documented default)
  • Rework cost per unit: 45 $ / unit (held at the documented default)
  • Share of build affected: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed containment cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable rework cost = units needing rework × rework cost per unit × share of build affected.
  • Total rework cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 28.6 $ / piece at these inputs.
  • Variable rework cost works out to 2,610 $ at these inputs.
  • Fixed containment cost works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share of build affected, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 2,860 $ (headline result)
  • Rework cost per unit: 28.6 $ / piece
  • Variable rework cost: 2,610 $
  • Fixed containment cost: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.