Semiconductor Advanced Packaging & Test worked example

Packaging Rework Cost at 50% share of pulled units actually reworkable: a worked example

Suppose share of pulled units actually reworkable falls to 50%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the cost of reworking failed advanced-package devices, including decap, re-attach and re-test labor plus line setup.

The inputs for this scenario

  • Failed units pulled for rework: 500 units (held at the documented default)
  • Rework labor and material per device: 18.5 $/unit (held at the documented default)
  • Share of pulled units actually reworkable: 50 % (the input this scenario stresses; the baseline uses 70)
  • Line changeover and setup charge: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total rework cost = units x per-device rework x reworkable% + setup charge.
  • Total packaging rework cost works out to 5,825 $ at these inputs, and this is the headline figure for the scenario.
  • Packaging rework cost per unit works out to 11.65 $ / piece at these inputs.
  • Variable packaging rework cost works out to 4,625 $ at these inputs.
  • Fixed packaging rework cost adder works out to 1,200 $ at these inputs.

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 24.1% below the baseline at 5,825 $.
  • It computes total rework cost and cost per pulled unit from failed volume, per-device rework, reworkable percentage, and a fixed setup charge. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total packaging rework cost: 5,825 $ (headline result)
  • Packaging rework cost per unit: 11.65 $ / piece
  • Variable packaging rework cost: 4,625 $
  • Fixed packaging rework cost adder: 1,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Rework Cost calculator, set share of pulled units actually reworkable to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.