Printed Electronics & Flexible Hybrid Electronics worked example

Rework Cost at 58% salvage capture factor: a worked example in printed electronics & flexible hybrid electronics

This worked example runs the rework cost numbers for a tougher week than the baseline: 58% salvage capture factor instead of the typical 80%. Rework Cost captures what it truly costs to salvage defective printed or flex-hybrid panels — component removal, re-print or re-attach, and re-inspection — rather than scrapping them.

The inputs for this scenario

  • Defective panels routed to rework: 100 units (held at the documented default)
  • Loaded rework rate per panel: 45 $ / unit (held at the documented default)
  • Salvage capture factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Rework setup fixed cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where salvage capture factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • Use it when dispositioning a defective lot, or when building a standard rework allowance into a job cost or quote. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Cost calculator, set salvage capture factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.