Wearable Medical Sensors worked example

Rework Cost at 61% units successfully reworked: a worked example in wearable medical sensors

Suppose units successfully reworked falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the rework cost for wearable medical sensors pulled off the line for repair or salvage.

The inputs for this scenario

  • Units Routed to Rework: 1,200 units (held at the documented default)
  • Rework Labor & Parts per Unit: 22 $ / unit (held at the documented default)
  • Units Successfully Reworked: 61 % (the input this scenario stresses; the baseline uses 85)
  • Rework Cell Setup Cost: 2,500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Rework cost = units reworked x labor & parts per unit x (% recovered) + cell setup.
  • Total rework cost works out to 18,604 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per unit works out to 15.5 $ / piece at these inputs.
  • Variable rework cost works out to 16,104 $ at these inputs.
  • Fixed rework cost adder works out to 2,500 $ at these inputs.

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 25.4% below the baseline at 18,604 $.
  • 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. 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

  • Total rework cost: 18,604 $ (headline result)
  • Rework cost per unit: 15.5 $ / piece
  • Variable rework cost: 16,104 $
  • Fixed rework cost adder: 2,500 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Cost calculator, set units successfully reworked to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.