Tube, Pipe & Profile Forming worked example

End-Forming Cost at 58% value-add capture factor for the operation: a worked example

Suppose value-add capture factor for the operation falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. End-Forming Cost estimates what it actually costs to expand, reduce, flare, bead or swage the ends of a batch of tubes, including a value-capture factor and the fixed setup that end-forming presses always carry.

The inputs for this scenario

  • Tube ends processed in the batch: 100 units (held at the documented default)
  • End-forming cost per tube end: 45 $ / unit (held at the documented default)
  • Value-add capture factor for the operation: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed setup and tooling charge: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: End-Forming 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 value-add capture factor for the operation sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • It multiplies quantity by the per-end rate and a capture factor, adds the fixed setup charge, and divides by quantity to give both total and per-piece end-forming cost. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

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 End-Forming Cost calculator, set value-add capture factor for the operation to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.