PPE & Infection Control Products worked example

Rework Cost at 99% recoverable share: a worked example in ppe & infection control products

What does the result look like when recoverable share reaches 99%? The full calculation is worked below with real intermediate numbers. A quality lead uses it to weigh reworking versus scrapping a lot of masks with off-center ear loops.

The inputs for this scenario

  • PPE units routed to rework: 2,500 units (unchanged)
  • Rework handling & relabel rate: 0.55 $/unit (unchanged)
  • Recoverable share (units salvaged after rework): 99 % (raised for this scenario; the documented default is 88)
  • Rework cell setup & re-QC cost: 260 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework = units reworked x handling rate x recoverable share% + setup & re-QC) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,621 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 0.65 $ / piece for rework cost per unit.
  • At this operating point the engine returns 1,361 $ for variable rework cost.
  • At this operating point the engine returns 260 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where recoverable share sits at 88% and the headline result is 1,470 $, this scenario comes in 10.29% above the baseline at 1,621 $.
  • A figure at this level is achievable when recoverable share is genuinely sustained, not just peaked for a shift. It assumes reworked units actually pass the second inspection; if your rework yield is below the recoverable share you enter, real cost per shippable unit will be higher than the figure shown.

Results at a glance

  • Total rework cost: 1,621 $ (headline result)
  • Rework cost per unit: 0.65 $ / piece
  • Variable rework cost: 1,361 $
  • Fixed rework cost adder: 260 $

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.