Specialty Films, Membranes & Barrier Materials worked example

Rework Cost at 58% share of rolls actually recoverable: a worked example in specialty films, membranes & barrier materials

This worked example runs the rework cost numbers for a tougher week than the baseline: 58% share of rolls actually recoverable instead of the typical 80%. Estimate the cost of reworking off-spec film rolls through rewinding, reslitting, relamination or recoating to recover them to spec.

The inputs for this scenario

  • Rolls sent back for rework: 60 rolls (held at the documented default)
  • Rework labor and material rate per roll: 45 $/roll (held at the documented default)
  • Share of rolls actually recoverable: 58 % (the input this scenario stresses; the baseline uses 80)
  • Rewinder changeover / setup charge: 500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total rework = rolls reworked x processing rate x recoverable share + changeover charge.
  • Total rework cost works out to 2,066 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 34.43 $ / piece at these inputs.
  • Variable rework cost works out to 1,566 $ at these inputs.
  • Fixed rework cost adder works out to 500 $ at these inputs.

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 22.33% below the baseline at 2,066 $.
  • Use it when deciding whether to rework or scrap a lot of off-spec rolls, and to budget rewinder time for a recovery run. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total rework cost: 2,066 $ (headline result)
  • Rework cost per unit: 34.43 $ / piece
  • Variable rework cost: 1,566 $
  • Fixed rework cost adder: 500 $

Run it with your numbers

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

Last reviewed 2026-05-12.