Precision Springs, Stampings & Micro-Formed Components worked example

Rework Cost at 54% share salvageable after re-forming or re-plating: a worked example in precision springs, stampings & micro-formed components

Here is what the math looks like when conditions slip. We hold every other input steady and drop share salvageable after re-forming or re-plating to 54%, then walk the calculation through step by step. Estimate the cost of re-forming, deburring or re-inspecting defective stampings and springs.

The inputs for this scenario

  • Stampings/springs flagged for rework: 8,000 parts (held at the documented default)
  • Secondary rework labor and consumables per part: 0.09 $/part (held at the documented default)
  • Share salvageable after re-forming or re-plating: 54 % (the input this scenario stresses; the baseline uses 75)
  • Sort, gauge and inspection setup charge: 140 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework cost = parts reworked x cost per part x salvageable share% + sort setup.
  • Total rework cost works out to 529 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 0.07 $ / piece at these inputs.
  • Variable rework cost works out to 389 $ at these inputs.
  • Fixed rework cost adder works out to 140 $ at these inputs.

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 22.24% below the baseline at 529 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share salvageable after re-forming or re-plating, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes every salvageable part passes after a single rework pass; parts that fail re-inspection and need a second pass or ultimately scrap are not captured, so real cost can run higher on marginal lots.

Results at a glance

  • Total rework cost: 529 $ (headline result)
  • Rework cost per unit: 0.07 $ / piece
  • Variable rework cost: 389 $
  • Fixed rework cost adder: 140 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Cost calculator, set share salvageable after re-forming or re-plating to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.