Thermal Spray, Hardfacing & Wear Coatings worked example

Rework Cost at 92% share of parts actually recoverable: a worked example in thermal spray, hardfacing & wear coatings

This scenario runs the rework cost calculation on the strong side: 92% share of parts actually recoverable, with every other input held at its documented default. Use it when rework cost in thermal spray, hardfacing and wear coatings is being put through a thermal spray, hardfacing and wear coatings weighted-cost review.

The inputs for this scenario

  • Coated parts requiring rework: 100 units (unchanged)
  • Rework labor + material cost per part: 45 $ / unit (unchanged)
  • Share of parts actually recoverable: 92 % (raised for this scenario; the documented default is 80)
  • Fixed setup / masking cost per batch: 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 parts actually recoverable sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • Use it when a coating lot comes back from bond, thickness or metallography checks and you must price the recovery run or justify a process change. 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

  • 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.