Space Payload & Avionics Manufacturing worked example

Flight Unit Rework at 98% rework yield loss factor: a worked example

This scenario runs the flight unit rework calculation on the strong side: 98% rework yield loss factor, with every other input held at its documented default. A production lead quoting the cost of pulling a flight unit back to the bench for rework and re-acceptance.

The inputs for this scenario

  • Rework Touch Hours: 60 hours (unchanged)
  • Loaded Technician Rate: 145 $/hr (unchanged)
  • Rework Yield Loss Factor: 98 % (raised for this scenario; the documented default is 85)
  • Retest and Inspection Charge: 4,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework = touch hours x loaded rate x yield loss factor + retest and inspection charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 12,726 $ for total flight unit rework cost, the number this scenario is built around.
  • At this operating point the engine returns 212 $ / piece for flight unit rework cost per unit.
  • At this operating point the engine returns 8,526 $ for variable flight unit rework cost.
  • At this operating point the engine returns 4,200 $ for fixed flight unit rework adder.

How this compares with the baseline

  • Against the tool's baseline example, where rework yield loss factor sits at 85% and the headline result is 11,595 $, this scenario comes in 9.75% above the baseline at 12,726 $.
  • Use it when weighing rework against scrap on a flight unit, budgeting rework labor for a production lot, or capturing cost of poor quality for a program. 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 flight unit rework cost: 12,726 $ (headline result)
  • Flight unit rework cost per unit: 212 $ / piece
  • Variable flight unit rework cost: 8,526 $
  • Fixed flight unit rework adder: 4,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.