Semiconductor Fab Equipment Manufacturing worked example

Module Rework Cost at 98% rework recovery success rate: a worked example

Push rework recovery success rate up to 98% and the picture changes. This example computes every intermediate figure at that operating point. A tool build manager facing leak or alignment failures uses it to size the rework spend on a batch of pulled modules.

The inputs for this scenario

  • Modules sent to rework: 15 modules (unchanged)
  • Rework labor & parts per module: 1,850 $/module (unchanged)
  • Rework recovery success rate: 98 % (raised for this scenario; the documented default is 85)
  • Diagnosis & teardown cost: 2,400 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework cost = modules reworked x rework cost per module x recovery rate% + diagnosis) to the inputs above produces each figure below.
  • At this operating point the engine returns 29,595 $ for total module rework cost, the number this scenario is built around.
  • At this operating point the engine returns 1,973 $ / piece for module rework cost per unit.
  • At this operating point the engine returns 27,195 $ for variable module rework cost.
  • At this operating point the engine returns 2,400 $ for fixed module rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where rework recovery success rate sits at 85% and the headline result is 25,988 $, this scenario comes in 13.88% above the baseline at 29,595 $.
  • Computes total module rework cost as modules times per-module cost times recovery rate, plus a fixed diagnosis and teardown charge, then divides by module count for cost per module. 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 module rework cost: 29,595 $ (headline result)
  • Module rework cost per unit: 1,973 $ / piece
  • Variable module rework cost: 27,195 $
  • Fixed module rework cost adder: 2,400 $

Run it with your numbers

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

Last reviewed 2026-05-12.