Nonwoven Materials & Technical Textiles worked example

Rework Cost at 98% reworkable share: a worked example in nonwoven materials & technical textiles

This scenario runs the rework cost calculation on the strong side: 98% reworkable share, with every other input held at its documented default. A quality lead deciding between reworking and scrapping a batch of off-spec rolls uses it to compare the labor cost against the material saved.

The inputs for this scenario

  • Rework labor hours: 16 hr (unchanged)
  • Loaded labor rate: 38 $/hr (unchanged)
  • Reworkable (salvageable) share: 98 % (raised for this scenario; the documented default is 85)
  • Line re-setup / threading charge: 150 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework cost = rework hours x loaded rate x reworkable share% + re-setup charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 746 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 46.62 $ / piece for rework cost per unit.
  • At this operating point the engine returns 596 $ for variable rework cost.
  • At this operating point the engine returns 150 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where reworkable share sits at 85% and the headline result is 667 $, this scenario comes in 11.85% above the baseline at 746 $.
  • Use it whenever a lot of nonwoven web is flagged off-spec and you must decide between reworking, downgrading, or scrapping it. 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 rework cost: 746 $ (headline result)
  • Rework cost per unit: 46.62 $ / piece
  • Variable rework cost: 596 $
  • Fixed rework cost adder: 150 $

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.