Specialty Films, Membranes & Barrier Materials worked example

Rework Cost at 92% share of rolls actually recoverable: a worked example in specialty films, membranes & barrier materials

This scenario runs the rework cost calculation on the strong side: 92% share of rolls actually recoverable, with every other input held at its documented default. A quality lead decides whether to rework a hold lot of barrier film or write it off as scrap.

The inputs for this scenario

  • Rolls sent back for rework: 60 rolls (unchanged)
  • Rework labor and material rate per roll: 45 $/roll (unchanged)
  • Share of rolls actually recoverable: 92 % (raised for this scenario; the documented default is 80)
  • Rewinder changeover / setup charge: 500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework = rolls reworked x processing rate x recoverable share + changeover charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,984 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 49.73 $ / piece for rework cost per unit.
  • At this operating point the engine returns 2,484 $ for variable rework cost.
  • At this operating point the engine returns 500 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of rolls actually recoverable sits at 80% and the headline result is 2,660 $, this scenario comes in 12.18% above the baseline at 2,984 $.
  • Use it when deciding whether to rework or scrap a lot of off-spec rolls, and to budget rewinder time for a recovery run. 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: 2,984 $ (headline result)
  • Rework cost per unit: 49.73 $ / piece
  • Variable rework cost: 2,484 $
  • Fixed rework cost adder: 500 $

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.