How do you calculate rework cost?

Multiply devices by the rework rate by the recoverable yield, then add the fixed cycle charge. For 300 devices at $12.50, 85% yield, plus a $900 cycle charge, total rework cost is $4,087.50.

What is the per-device rework cost?

Divide total cost by the number of devices. Here $4,087.50 across 300 devices is $13.625 per device, slightly above the raw $12.50 rate because the fixed cycle charge is spread across the lot.

Why include recoverable yield?

Not every reworked sterile device survives re-processing. The 85% yield means you effectively pay the variable rate against recoverable units, giving $3,187.50 in variable cost before the $900 fixed adder.

When is rework cheaper than scrapping?

When total rework cost stays below the full remanufacturing plus new-sterilization cost. Compare this calculator's total against your build-plus-cycle cost for the same quantity.

Why is per-device cost higher than the rework rate?

The fixed cycle setup charge is spread across the lot. At 300 devices the $900 charge adds $3 per unit, pushing the per-device figure from $12.50 to $13.625.

How does lot size affect rework cost per device?

Larger lots dilute the fixed cycle charge across more units, lowering per-device cost. Reworking a handful of devices through a full cycle is expensive because that $900 charge is spread thin.

Sterilization & Sterile Barrier Manufacturing calculator

Rework Cost Calculator

Rework cost captures what it actually costs to salvage a sterile barrier lot that failed inspection, re-inspecting, re-sealing pouches, and paying for another sterilization cycle. Sterilization operations and cost accountants use it to decide whether rework is cheaper than scrapping and re-manufacturing, since a full sterilization cycle carries a heavy fixed charge whether you re-run one device or a hundred. The recoverable yield term is what makes this specific to sterile work: not every reworked device survives, so you pay the variable rate against the units you realistically recover, then add the fixed cycle charge on top. This calculator returns both the total and the per-device cost so you can compare against scrap-and-remake.

What this calculator does

Estimate the cost to repackage and re-sterilize devices pulled for sterile barrier or cycle nonconformances.
A production supervisor uses this to compare reworking a flagged sub-lot against scrapping it outright.
It computes total rework cost as devices times rate times recoverable yield plus a fixed cycle setup charge, then divides by devices for a per-unit figure.

Formula used

Total rework cost = devices reworked x rework rate x recoverable yield % + cycle setup charge
Per-device rework cost = total rework cost / devices reworked

Inputs explained

Devices requiring rework:
Rework labor and re-sterilize rate:
Recoverable yield after rework:
Re-sterilization cycle setup charge:

How to use the result

Use it when a lot fails and you must choose between reworking and re-sterilizing versus scrapping and rebuilding.
It assumes one re-sterilization cycle; a device that fails rework and needs a second cycle, or that is destroyed by re-processing, is not modeled and would raise the true cost.

Current U.S. benchmarks

U.S. manufacturing runs at 75.6% of capacity with new factory orders at $657B per month (Federal Reserve and Census, May 2026).

Common questions

How do you calculate rework cost? Multiply devices by the rework rate by the recoverable yield, then add the fixed cycle charge. For 300 devices at $12.50, 85% yield, plus a $900 cycle charge, total rework cost is $4,087.50.
What is the per-device rework cost? Divide total cost by the number of devices. Here $4,087.50 across 300 devices is $13.625 per device, slightly above the raw $12.50 rate because the fixed cycle charge is spread across the lot.
Why include recoverable yield? Not every reworked sterile device survives re-processing. The 85% yield means you effectively pay the variable rate against recoverable units, giving $3,187.50 in variable cost before the $900 fixed adder.
When is rework cheaper than scrapping? When total rework cost stays below the full remanufacturing plus new-sterilization cost. Compare this calculator's total against your build-plus-cycle cost for the same quantity.
Why is per-device cost higher than the rework rate? The fixed cycle setup charge is spread across the lot. At 300 devices the $900 charge adds $3 per unit, pushing the per-device figure from $12.50 to $13.625.

Last reviewed 2026-05-12.