Sterilization & Sterile Barrier Manufacturing worked example

Rework Cost at 61% recoverable yield after rework: a worked example in sterilization & sterile barrier manufacturing

Here is what the math looks like when conditions slip. We hold every other input steady and drop recoverable yield after rework to 61%, then walk the calculation through step by step. Estimate the cost to repackage and re-sterilize devices pulled for sterile barrier or cycle nonconformances.

The inputs for this scenario

  • Devices requiring rework: 300 devices (held at the documented default)
  • Rework labor and re-sterilize rate: 12.5 $/device (held at the documented default)
  • Recoverable yield after rework: 61 % (the input this scenario stresses; the baseline uses 85)
  • Re-sterilization cycle setup charge: 900 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total rework cost = devices reworked x rework rate x recoverable yield % + cycle setup charge.
  • Total rework cost works out to 3,188 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 10.63 $ / piece at these inputs.
  • Variable rework cost works out to 2,288 $ at these inputs.
  • Fixed rework cost adder works out to 900 $ at these inputs.

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 22.02% below the baseline at 3,188 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to recoverable yield after rework, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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.

Results at a glance

  • Total rework cost: 3,188 $ (headline result)
  • Rework cost per unit: 10.63 $ / piece
  • Variable rework cost: 2,288 $
  • Fixed rework cost adder: 900 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Cost calculator, set recoverable yield after rework to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.