Space Payload & Avionics Manufacturing worked example

Flight Unit Rework at 61% rework yield loss factor: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop rework yield loss factor to 61%, then walk the calculation through step by step. Estimates the labor and retest cost to rework a space flight unit after a defect or design change.

The inputs for this scenario

  • Rework Touch Hours: 60 hours (held at the documented default)
  • Loaded Technician Rate: 145 $/hr (held at the documented default)
  • Rework Yield Loss Factor: 61 % (the input this scenario stresses; the baseline uses 85)
  • Retest and Inspection Charge: 4,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total rework = touch hours x loaded rate x yield loss factor + retest and inspection charge.
  • Total flight unit rework cost works out to 9,507 $ at these inputs, and this is the headline figure for the scenario.
  • Flight unit rework cost per unit works out to 158 $ / piece at these inputs.
  • Variable flight unit rework cost works out to 5,307 $ at these inputs.
  • Fixed flight unit rework adder works out to 4,200 $ at these inputs.

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 18.01% below the baseline at 9,507 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to rework yield loss factor, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The yield loss factor is a single blended number; a rework that itself introduces a new defect and loops back through test is not captured by one pass.

Results at a glance

  • Total flight unit rework cost: 9,507 $ (headline result)
  • Flight unit rework cost per unit: 158 $ / piece
  • Variable flight unit rework cost: 5,307 $
  • Fixed flight unit rework adder: 4,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Flight Unit Rework calculator, set rework yield loss factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.