Sheet Metal Stamping & Press Lines worked example

Rework Cost at 92% share of flagged parts actually reworked: a worked example in sheet metal stamping & press lines

What does the result look like when share of flagged parts actually reworked reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when rework cost in sheet metal stamping and press lines is being put through a sheet metal stamping and press lines weighted-cost review.

The inputs for this scenario

  • Stamped parts flagged for rework: 100 units (unchanged)
  • Rework labor & handling per part: 45 $ / unit (unchanged)
  • Share of flagged parts actually reworked: 92 % (raised for this scenario; the documented default is 80)
  • Fixed rework setup cost (die touch-up, inspection): 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework Cost cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where share of flagged parts actually reworked sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when share of flagged parts actually reworked is genuinely sustained, not just peaked for a shift. It assumes a single flat per-part rework rate; mixed defect types (deburr vs. straighten vs. re-pierce) have very different labor and should be modeled as separate runs.

Results at a glance

  • Weighted cost: 4,390 $ (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

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.