Plating, Anodizing & Surface Treatment worked example

Rework Cost at 98% salvageable share: a worked example in plating, anodizing & surface treatment

This scenario runs the rework cost calculation on the strong side: 98% salvageable share, with every other input held at its documented default. Use it when a plating or anodizing lot fails inspection and you need to price stripping and re-running the affected parts.

The inputs for this scenario

  • Parts stripped and re-finished: 40 parts (unchanged)
  • Rework cost per part: 3.75 $/part (unchanged)
  • Salvageable share: 98 % (raised for this scenario; the documented default is 85)
  • Strip-bath and inspection adder: 90 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework cost = parts x rework cost per part x salvageable share% + strip-bath and inspection adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 237 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 5.93 $ / piece for rework cost per unit.
  • At this operating point the engine returns 147 $ for variable rework cost.
  • At this operating point the engine returns 90 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where salvageable share sits at 85% and the headline result is 218 $, this scenario comes in 8.97% above the baseline at 237 $.
  • Use it after inspection rejects a rack or lot and you need to decide between re-finishing and scrapping, or to book cost-of-quality for a defect trend. 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: 237 $ (headline result)
  • Rework cost per unit: 5.93 $ / piece
  • Variable rework cost: 147 $
  • Fixed rework cost adder: 90 $

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.