Finishing worked example

Coating Defect Cost with defective coated parts of 50 parts: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop defective coated parts to 50 parts, then walk the calculation through step by step. Calculate reject, rework, stripping, and recoating cost from defective parts and cost assumptions.

The inputs for this scenario

  • Defective coated parts: 50 parts (the input this scenario stresses; the baseline uses 100)
  • Rework cost per defect: 2.5 $ / part (held at the documented default)
  • Inspection and sorting labor: 150 $ (held at the documented default)
  • Scrap or downtime burden: 75 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total cost = quantity × unit cost + labor/downtime + overhead.
  • Total cost works out to 350 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per piece works out to 7 $ / piece at these inputs.
  • Variable cost works out to 125 $ at these inputs.
  • Fixed adders works out to 225 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where defective coated parts sits at 100 parts and the headline result is 475 $, this scenario comes in 26.32% below the baseline at 350 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to defective coated parts, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It captures direct and burden costs but not downstream effects like a lost customer, expedite freight, or warranty claims from defects that escape.

Results at a glance

  • Total cost: 350 $ (headline result)
  • Cost per piece: 7 $ / piece
  • Variable cost: 125 $
  • Fixed adders: 225 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Coating Defect Cost calculator, set defective coated parts to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.