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Rework Loop Capacity Calculator

Use this calculator when rejects can be repaired and returned to the production line. It helps quality, manufacturing, and operations teams check whether rework capacity can keep up without starving the main flow or growing WIP.

What this calculator does

  • Estimate good units recovered through a rework loop from rework positions, cycles, uptime, and recovery yield.
  • a quality or production engineer needs to know whether the rework loop can absorb expected defects
  • The result estimates how many good units per hour the rework loop can return to production.

Formula used

  • Gross rework attempts = rework positions × cycles per position-hour
  • Recovered good units = gross attempts × uptime × recovery yield

Inputs explained

  • Active rework positions: Count benches, fixtures, operators, or rework stations available for the defect type.
  • Rework cycles per position-hour: Use the rate at which one position can complete rework attempts.
  • Rework loop uptime: Reduce for missing parts, engineering holds, staffing gaps, and inspection waits.
  • Successful rework recovery yield: Use the percentage of reworked units returned as good output.

How to use the result

  • Use it when defects rise, rework WIP grows, or a main line depends on recovered parts to meet schedule.
  • It does not judge whether rework is economically justified or allowed by quality requirements.

Common questions

  • What is Rework Loop Capacity for? Estimate good units recovered through a rework loop from rework positions, cycles, uptime, and recovery yield.
  • What information do I need before using it? You need active rework positions, cycles per position-hour, rework uptime, and recovery yield.
  • When is the result only an estimate? The result is only an estimate when defect mix, rework time, or recovery yield changes by failure mode.
  • How can I use the result on the line? Use recovered capacity to decide whether to add rework labor, quarantine defects, or fix the upstream process first.

Last reviewed 2026-05-12.