Thermal Spray, Hardfacing & Wear Coatings worked example

Rework Cost at 58% share of parts actually recoverable: a worked example in thermal spray, hardfacing & wear coatings

Here is what the math looks like when conditions slip. We hold every other input steady and drop share of parts actually recoverable to 58%, then walk the calculation through step by step. Rework Cost tells a thermal spray shop what it actually spends re-blasting, re-masking and re-spraying coatings that failed inspection — bond-test rejects, out-of-tolerance thickness, or spalled hardfacing.

The inputs for this scenario

  • Coated parts requiring rework: 100 units (held at the documented default)
  • Rework labor + material cost per part: 45 $ / unit (held at the documented default)
  • Share of parts actually recoverable: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed setup / masking cost per batch: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share of parts actually recoverable, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a single blended per-part rework rate; parts needing full strip-and-recoat versus a light touch-up cost very differently and should be modeled separately.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.