Veterinary Device & Animal Health Products worked example

Rework Cost at 98% reworkable yield: a worked example in veterinary device & animal health products

This scenario runs the rework cost calculation on the strong side: 98% reworkable yield, with every other input held at its documented default. A quality engineer uses it to size the rework exposure on a lot of injectable applicators that failed a dimensional check.

The inputs for this scenario

  • Devices Reworked: 500 units (unchanged)
  • Rework Labor & Materials Rate: 6.4 $/unit (unchanged)
  • Reworkable Yield: 98 % (raised for this scenario; the documented default is 85)
  • Line Changeover & Re-Inspection: 850 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total rework = devices reworked x rework rate x reworkable yield% + changeover/re-inspection) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,986 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 7.97 $ / piece for rework cost per unit.
  • At this operating point the engine returns 3,136 $ for variable rework cost.
  • At this operating point the engine returns 850 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where reworkable yield sits at 85% and the headline result is 3,570 $, this scenario comes in 11.65% above the baseline at 3,986 $.
  • Use it during scrap-versus-rework decisions, when quoting the recovery cost of a nonconformance, or when trending rework spend against production volume. 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

  • Total rework cost: 3,986 $ (headline result)
  • Rework cost per unit: 7.97 $ / piece
  • Variable rework cost: 3,136 $
  • Fixed rework cost adder: 850 $

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.