Motors, Generators & Electrification Equipment worked example

Rework from Failed Hipot with motors failing hipot of 50 units: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop motors failing hipot to 50 units, then walk the calculation through step by step. Estimate the rework cost for motors or windings that failed hipot (high-potential) testing so teams can quote the rework, compare cost scenarios, and review margin risk.

The inputs for this scenario

  • Motors failing hipot: 50 units (the input this scenario stresses; the baseline uses 100)
  • Rework cost per failed motor: 2.5 $ / unit (held at the documented default)
  • Fixed teardown and fixturing cost: 75 $ (held at the documented default)
  • Retest labor and overhead adder: 25 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total hipot rework cost = units failing hipot × rework cost per unit + fixed rework cost + labor and test overhead adder.
  • Total hipot rework cost works out to 225 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 4.5 $ / piece at these inputs.
  • Variable rework cost per unit works out to 125 $ at these inputs.
  • Fixed hipot rework cost works out to 100 $ at these inputs.

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 35.71% below the baseline at 225 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to motors failing hipot, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats every failed motor as reworkable at the same cost; units that are actually scrapped, or faults that vary widely in repair effort, need a separate scrap line or a blended per-unit rate.

Results at a glance

  • Total hipot rework cost: 225 $ (headline result)
  • Rework cost per unit: 4.5 $ / piece
  • Variable rework cost per unit: 125 $
  • Fixed hipot rework cost: 100 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework from Failed Hipot calculator, set motors failing hipot to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.