Wearable Medical Sensors worked example

Rework Cost at 98% units successfully reworked: a worked example in wearable medical sensors

Push units successfully reworked up to 98% and the picture changes. This example computes every intermediate figure at that operating point. A production engineer costing a rework loop for sensors failing flex-circuit or adhesive inspection.

The inputs for this scenario

  • Units Routed to Rework: 1,200 units (unchanged)
  • Rework Labor & Parts per Unit: 22 $ / unit (unchanged)
  • Units Successfully Reworked: 98 % (raised for this scenario; the documented default is 85)
  • Rework Cell Setup Cost: 2,500 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Rework cost = units reworked x labor & parts per unit x (% recovered) + cell setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 28,372 $ for total rework cost, the number this scenario is built around.
  • At this operating point the engine returns 23.64 $ / piece for rework cost per unit.
  • At this operating point the engine returns 25,872 $ for variable rework cost.
  • At this operating point the engine returns 2,500 $ for fixed rework cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where units successfully reworked sits at 85% and the headline result is 24,940 $, this scenario comes in 13.76% above the baseline at 28,372 $.
  • It computes total rework cost and the cost per reworked unit from the number of units routed, per-unit labor and parts, the recovery rate, and a one-time cell setup 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

  • Total rework cost: 28,372 $ (headline result)
  • Rework cost per unit: 23.64 $ / piece
  • Variable rework cost: 25,872 $
  • Fixed rework cost adder: 2,500 $

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.