Robotic End-of-Arm Tooling worked example

Rework Cost at 40% share needing true rework: a worked example in robotic end-of-arm tooling

Here is what the math looks like when conditions slip. We hold every other input steady and drop share needing true rework to 40%, then walk the calculation through step by step. Estimate the cost of reworking assembled EOAT grippers or tool-changers that fail functional or leak-down test.

The inputs for this scenario

  • EOAT assemblies flagged: 70 units (held at the documented default)
  • Disassembly and rebuild labor per unit: 110 $ / unit (held at the documented default)
  • Share needing true rework: 40 % (the input this scenario stresses; the baseline uses 55)
  • Test fixture and root-cause setup: 900 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework cost = EOAT assemblies flagged x disassembly and rebuild labor per unit x share needing true rework + test fixture and root-cause setup.
  • Total rework cost works out to 3,980 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 56.86 $ / piece at these inputs.
  • Variable rework cost works out to 3,080 $ at these inputs.
  • Fixed rework cost adder works out to 900 $ at these inputs.

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 22.49% below the baseline at 3,980 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share needing true rework, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It uses one average labor cost per unit, so mixed complexity — a simple two-finger gripper versus a multi-sensor tool changer — will skew the true per-assembly cost.

Results at a glance

  • Total rework cost: 3,980 $ (headline result)
  • Rework cost per unit: 56.86 $ / piece
  • Variable rework cost: 3,080 $
  • Fixed rework cost adder: 900 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Cost calculator, set share needing true rework to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.