Welding & Fabrication worked example

Weld Rework Cost with weldments reworked of 30 parts: a worked example

What does the result look like when weldments reworked reaches 30 parts? The full calculation is worked below with real intermediate numbers. Use it after a weld defect callout to total the cost of grinding out, re-prepping, re-welding, and re-inspecting affected weldments.

The inputs for this scenario

  • Weldments reworked: 30 parts (raised for this scenario; the documented default is 12)
  • Per-part weld rework cost: 35 $ / part (unchanged)
  • Grinding and re-weld setup cost: 125 $ (unchanged)
  • Welder rework labor with burden: 480 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total weld rework cost = weldments reworked × per-part weld rework cost + grinding and re-weld setup cost + welder rework labor with burden) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,655 $ for total weld rework cost, the number this scenario is built around.
  • At this operating point the engine returns 55.17 $ / piece for weld rework cost per weldment.
  • At this operating point the engine returns 1,050 $ for per-part weld rework cost.
  • At this operating point the engine returns 605 $ for setup and labor with burden.

How this compares with the baseline

  • Against the tool's baseline example, where weldments reworked sits at 12 parts and the headline result is 1,025 $, this scenario comes in 61.46% above the baseline at 1,655 $.
  • A figure at this level is achievable when weldments reworked is genuinely sustained, not just peaked for a shift. It assumes the reworked welds pass on the second pass; scrap after failed rework belongs in a separate scrap calculation, not here.

Results at a glance

  • Total weld rework cost: 1,655 $ (headline result)
  • Weld rework cost per weldment: 55.17 $ / piece
  • Per-part weld rework cost: 1,050 $
  • Setup and labor with burden: 605 $

Run it with your numbers

  • Every input above is editable in the live Weld Rework Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.