Sterilization & Sterile Barrier Manufacturing worked example

Rework Cost at 98% recoverable yield after rework: a worked example in sterilization & sterile barrier manufacturing

This scenario runs the rework cost calculation on the strong side: 98% recoverable yield after rework, with every other input held at its documented default. A production supervisor uses this to compare reworking a flagged sub-lot against scrapping it outright.

The inputs for this scenario

  • Devices requiring rework: 300 devices (unchanged)
  • Rework labor and re-sterilize rate: 12.5 $/device (unchanged)
  • Recoverable yield after rework: 98 % (raised for this scenario; the documented default is 85)
  • Re-sterilization cycle setup charge: 900 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework cost = devices reworked x rework rate x recoverable yield % + cycle setup charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,575 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 15.25 $ / piece for rework cost per unit.
  • At this operating point the engine returns 3,675 $ for variable rework cost.
  • At this operating point the engine returns 900 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where recoverable yield after rework sits at 85% and the headline result is 4,088 $, this scenario comes in 11.93% above the baseline at 4,575 $.
  • Use it when a lot fails and you must choose between reworking and re-sterilizing versus scrapping and rebuilding. 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: 4,575 $ (headline result)
  • Rework cost per unit: 15.25 $ / piece
  • Variable rework cost: 3,675 $
  • Fixed rework cost adder: 900 $

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.