Sheet Metal Stamping & Press Lines worked example

Rework Cost at 58% share of flagged parts actually reworked: a worked example in sheet metal stamping & press lines

Suppose share of flagged parts actually reworked falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Rework cost is the total dollars a stamping shop spends salvaging parts that came off the press with burrs, springback, wrinkles, or dimensional drift instead of scrapping them.

The inputs for this scenario

  • Stamped parts flagged for rework: 100 units (held at the documented default)
  • Rework labor & handling per part: 45 $ / unit (held at the documented default)
  • Share of flagged parts actually reworked: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed rework setup cost (die touch-up, inspection): 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • It computes total rework dollars for a lot as variable salvage cost across the parts you actually rework plus a fixed setup charge, then divides by the flagged quantity for a per-piece figure. 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

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.