Welding & Fabrication worked example

Weld Rework Cost with weldments reworked of 6 parts: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop weldments reworked to 6 parts, then walk the calculation through step by step. Estimate weld rework cost from rework quantity, per-part rework cost, grinding and re-weld setup, and labor with burden.

The inputs for this scenario

  • Weldments reworked: 6 parts (the input this scenario stresses; the baseline uses 12)
  • Per-part weld rework cost: 35 $ / part (held at the documented default)
  • Grinding and re-weld setup cost: 125 $ (held at the documented default)
  • Welder rework labor with burden: 480 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total weld rework cost = weldments reworked × per-part weld rework cost + grinding and re-weld setup cost + welder rework labor with burden.
  • Total weld rework cost works out to 815 $ at these inputs, and this is the headline figure for the scenario.
  • Weld rework cost per weldment works out to 136 $ / piece at these inputs.
  • Per-part weld rework cost works out to 210 $ at these inputs.
  • Setup and labor with burden works out to 605 $ at these inputs.

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 20.49% below the baseline at 815 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to weldments reworked, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 815 $ (headline result)
  • Weld rework cost per weldment: 136 $ / piece
  • Per-part weld rework cost: 210 $
  • Setup and labor with burden: 605 $

Run it with your numbers

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

Last reviewed 2026-05-12.