Robotic End-of-Arm Tooling worked example

Rework Cost at 63% share needing true rework: a worked example in robotic end-of-arm tooling

Push share needing true rework up to 63% and the picture changes. This example computes every intermediate figure at that operating point. you want to quantify what a batch of failed gripper or tool-changer builds will cost to rebuild and retest before shipment.

The inputs for this scenario

  • EOAT assemblies flagged: 70 units (unchanged)
  • Disassembly and rebuild labor per unit: 110 $ / unit (unchanged)
  • Share needing true rework: 63 % (raised for this scenario; the documented default is 55)
  • Test fixture and root-cause setup: 900 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework cost = EOAT assemblies flagged x disassembly and rebuild labor per unit x share needing true rework + test fixture and root-cause setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,751 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 82.16 $ / piece for rework cost per unit.
  • At this operating point the engine returns 4,851 $ for variable rework cost.
  • At this operating point the engine returns 900 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where share needing true rework sits at 55% and the headline result is 5,135 $, this scenario comes in 12% above the baseline at 5,751 $.
  • It computes the total dollars to rework the fraction of flagged EOAT assemblies that genuinely need teardown and rebuild, plus a fixed root-cause setup cost, and the cost per flagged assembly. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total rework cost: 5,751 $ (headline result)
  • Rework cost per unit: 82.16 $ / piece
  • Variable rework cost: 4,851 $
  • Fixed rework cost adder: 900 $

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.