Switchgear, Panelboards & Electrical Distribution worked example

Rework Cost at 92% share of defects captured before ship: a worked example in switchgear, panelboards & electrical distribution

Push share of defects captured before ship up to 92% and the picture changes. This example computes every intermediate figure at that operating point. Use it when rework cost in switchgear, panelboards and electrical distribution is being put through a switchgear, panelboards and electrical distribution weighted-cost review.

The inputs for this scenario

  • Panels requiring rework: 100 units (unchanged)
  • Rework labor and material rate per panel: 45 $ / unit (unchanged)
  • Share of defects captured before ship: 92 % (raised for this scenario; the documented default is 80)
  • Fixed rework setup and admin cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework Cost cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where share of defects captured before ship sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • Multiplies the number of reworked panels by the per-panel rate and a capture factor, adds fixed cost, and returns total and per-piece rework cost. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Weighted cost: 4,390 $ (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

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.