Surgical Robotics Manufacturing worked example

Rework Cost at 58% share of subassemblies repairable: a worked example in surgical robotics manufacturing

This worked example runs the rework cost numbers for a tougher week than the baseline: 58% share of subassemblies repairable instead of the typical 80%. Estimate the cost to disassemble, repair, and requalify nonconforming surgical robot subassemblies.

The inputs for this scenario

  • Robotic subassemblies sent to rework: 60 subassemblies (held at the documented default)
  • Fully-loaded rework labor cost per subassembly: 185 $/subassembly (held at the documented default)
  • Share of subassemblies repairable (not scrapped): 58 % (the input this scenario stresses; the baseline uses 80)
  • Retest and requalification fee: 3,500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total rework cost = subassemblies reworked x labor rate x repairable share % + retest fee.
  • Total rework cost works out to 9,938 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 166 $ / piece at these inputs.
  • Variable rework cost works out to 6,438 $ at these inputs.
  • Fixed rework cost adder works out to 3,500 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where share of subassemblies repairable sits at 80% and the headline result is 12,380 $, this scenario comes in 19.73% below the baseline at 9,938 $.
  • Use it when weighing rework against scrap, costing a nonconformance disposition, or building the business case to fix a recurring defect. 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: 9,938 $ (headline result)
  • Rework cost per unit: 166 $ / piece
  • Variable rework cost: 6,438 $
  • Fixed rework cost adder: 3,500 $

Run it with your numbers

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

Last reviewed 2026-05-12.