Single-Use Bioprocess Assemblies worked example

Rework Cost at 98% first-pass rework yield: a worked example in single-use bioprocess assemblies

This scenario runs the rework cost calculation on the strong side: 98% first-pass rework yield, with every other input held at its documented default. A cleanroom assembly cell deciding whether to rework or scrap a lot of mis-welded tubing manifolds.

The inputs for this scenario

  • Assemblies Reworked: 30 assemblies (unchanged)
  • Rework Labor & Components: 145 $/assembly (unchanged)
  • First-Pass Rework Yield: 98 % (raised for this scenario; the documented default is 85)
  • Re-Inspection Setup Cost: 650 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework cost = reworked assemblies x rework labor & components x first-pass yield + re-inspection setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,913 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 164 $ / piece for rework cost per unit.
  • At this operating point the engine returns 4,263 $ for variable rework cost.
  • At this operating point the engine returns 650 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass rework yield sits at 85% and the headline result is 4,348 $, this scenario comes in 13.01% above the baseline at 4,913 $.
  • Use it when a batch of assemblies fails inspection and you must decide between rework and scrap, or when building the rework line item of a cost-of-poor-quality or quote-adjustment analysis. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total rework cost: 4,913 $ (headline result)
  • Rework cost per unit: 164 $ / piece
  • Variable rework cost: 4,263 $
  • Fixed rework cost adder: 650 $

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.