Semiconductor Advanced Packaging & Test worked example

Packaging Rework Cost at 81% share of pulled units actually reworkable: a worked example

What does the result look like when share of pulled units actually reworkable reaches 81%? The full calculation is worked below with real intermediate numbers. An OSAT or fab packaging team sizing the dollar exposure of a flip-chip or fan-out lot that failed final test before deciding to rework or scrap.

The inputs for this scenario

  • Failed units pulled for rework: 500 units (unchanged)
  • Rework labor and material per device: 18.5 $/unit (unchanged)
  • Share of pulled units actually reworkable: 81 % (raised for this scenario; the documented default is 70)
  • Line changeover and setup charge: 1,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework cost = units x per-device rework x reworkable% + setup charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 8,693 $ for total packaging rework cost, the number this scenario is built around.
  • At this operating point the engine returns 17.39 $ / piece for packaging rework cost per unit.
  • At this operating point the engine returns 7,493 $ for variable packaging rework cost.
  • At this operating point the engine returns 1,200 $ for fixed packaging rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of pulled units actually reworkable sits at 70% and the headline result is 7,675 $, this scenario comes in 13.26% above the baseline at 8,693 $.
  • A figure at this level is achievable when share of pulled units actually reworkable is genuinely sustained, not just peaked for a shift. It applies one flat per-device rework rate and does not model multi-pass rework, escalating cost by defect type, or the risk that reworked units fail again downstream.

Results at a glance

  • Total packaging rework cost: 8,693 $ (headline result)
  • Packaging rework cost per unit: 17.39 $ / piece
  • Variable packaging rework cost: 7,493 $
  • Fixed packaging rework cost adder: 1,200 $

Run it with your numbers

  • Every input above is editable in the live Packaging Rework Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.