Motors, Generators & Electrification Equipment worked example

Rework from Failed Hipot with motors failing hipot of 250 units: a worked example

This scenario runs the rework from failed hipot calculation on the strong side: motors failing hipot of 250 units, with every other input held at its documented default. Use it when hipot rework is being quoted and you need a number you can defend on a phone call.

The inputs for this scenario

  • Motors failing hipot: 250 units (raised for this scenario; the documented default is 100)
  • Rework cost per failed motor: 2.5 $ / unit (unchanged)
  • Fixed teardown and fixturing cost: 75 $ (unchanged)
  • Retest labor and overhead adder: 25 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total hipot rework cost = units failing hipot × rework cost per unit + fixed rework cost + labor and test overhead adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 725 $ for total hipot rework cost, the number this scenario is built around.
  • At this operating point the engine returns 2.9 $ / piece for rework cost per unit.
  • At this operating point the engine returns 625 $ for variable rework cost per unit.
  • At this operating point the engine returns 100 $ for fixed hipot rework cost.

How this compares with the baseline

  • Against the tool's baseline example, where motors failing hipot sits at 100 units and the headline result is 350 $, this scenario comes in 107% above the baseline at 725 $.
  • Use it after a hipot failure spike to quantify the rework hit, or when building a quality budget that anticipates a known failure rate. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total hipot rework cost: 725 $ (headline result)
  • Rework cost per unit: 2.9 $ / piece
  • Variable rework cost per unit: 625 $
  • Fixed hipot rework cost: 100 $

Run it with your numbers

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

Last reviewed 2026-05-12.