Precision Springs, Stampings & Micro-Formed Components worked example

Rework Cost at 86% share salvageable after re-forming or re-plating: a worked example in precision springs, stampings & micro-formed components

This scenario runs the rework cost calculation on the strong side: 86% share salvageable after re-forming or re-plating, with every other input held at its documented default. A quality engineer weighing sort-and-rework against scrap on a flagged lot uses it to size the recovery cost.

The inputs for this scenario

  • Stampings/springs flagged for rework: 8,000 parts (unchanged)
  • Secondary rework labor and consumables per part: 0.09 $/part (unchanged)
  • Share salvageable after re-forming or re-plating: 86 % (raised for this scenario; the documented default is 75)
  • Sort, gauge and inspection setup charge: 140 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework cost = parts reworked x cost per part x salvageable share% + sort setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 759 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 0.09 $ / piece for rework cost per unit.
  • At this operating point the engine returns 619 $ for variable rework cost.
  • At this operating point the engine returns 140 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where share salvageable after re-forming or re-plating sits at 75% and the headline result is 680 $, this scenario comes in 11.65% above the baseline at 759 $.
  • Use it at lot disposition, when incoming, in-process or final inspection flags a nonconformance and you must decide between reworking the affected parts or scrapping and rerunning. 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: 759 $ (headline result)
  • Rework cost per unit: 0.09 $ / piece
  • Variable rework cost: 619 $
  • Fixed rework cost adder: 140 $

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.