How do you calculate harness rework cost?

Multiply the harnesses handled by the rework labor rate and the defect occurrence percentage, then add scrapped material. With 120 harnesses, $28/unit, 15% defects and $350 scrap, that is 120 x 28 x 0.15 + 350 = $854 total.

What is the rework cost per harness in this example?

Divide the $854 total by the 120 harnesses reworked to get $7.12 per unit. That blended figure spreads the fixed $350 scrap across every harness, so it drops fast as volume rises.

What is the difference between variable and fixed rework cost here?

The variable cost of $504 is the labor tied to the 15% that actually needed rework (120 x 28 x 0.15). The fixed $350 is scrapped material you eat regardless of how many units you rework.

What is a good harness rework cost per unit?

There is no universal target, but on automotive and industrial harness lines a healthy program keeps rework under 2-4% of total build cost. If your per-unit rework rivals your per-unit build labor, the process is out of control.

How do I lower harness rework cost?

Attack the defect occurrence first since it multiplies the labor term. Better crimp die maintenance, poka-yoke connector seating, and inline continuity testing cut the 15% far more effectively than shaving the labor rate.

Should retest time be included in the labor rate?

Yes if you retest every reworked harness. This model puts all touch time into the rework labor rate, so fold the operator's retest minutes into that $28/unit figure rather than leaving it out.

Wire Harness, Cable & Electromechanical Assembly calculator

Harness Rework Cost Calculator

Harness Rework Cost puts a dollar figure on the hidden tax of pulling, re-terminating and re-testing wire harnesses that failed continuity, pull-test or visual inspection. Harness build supervisors, quality engineers and cost estimators use it to translate a first-pass yield miss into money a plant manager will act on. On a labor-heavy harness line, rework is where margin quietly disappears, and this calculator splits the spend into the variable labor portion and the fixed scrap adder so you know which lever to pull.

What this calculator does

Estimate harness rework cost from repair labor, the defect occurrence rate and material scrapped during the repair loop.
A quality engineer sizing the cost of a crimp or continuity failure across a lot uses it to justify a process fix versus living with the rework.
It computes total rework cost as harnesses x rework labor x defect occurrence, plus a fixed scrapped-material adder, then divides by harnesses reworked for a per-unit figure.

Formula used

Total = harnesses x rework labor rate x defect occurrence% + scrapped material
Per reworked harness = Total / harnesses reworked

Inputs explained

Harnesses reworked this run:
Rework touch labor per harness:
Defect occurrence rate:
Scrapped wire and connector material:

How to use the result

Use it after a build run or containment event when you need to quantify rework spend for a corrective-action report, a cost-of-quality review, or a quote loading factor.
It treats defect occurrence and labor as flat averages; it understates cost where one defect forces a full re-harness instead of a spot repair, and it excludes retest fixture time and expedite freight.

Current U.S. benchmarks

The producer price index for copper and brass mill shapes stands at 559.593 (BLS, May 2026), up 76.8% from a year earlier. Quotes priced off last quarter's material cost miss this move. Global copper trades at $13,484 per tonne (IMF via FRED, May 2026).
Manufacturing hourly earnings average $30.27 (BLS, Jun 2026), up 4.4% from a year earlier. Median machinist pay is $28.24/hr (OEWS 2025), with state medians on each state page. Manufacturers have 529k open positions nationally (BLS JOLTS).
The U.S. has 5,397 electrical equipment and appliances establishments employing about 369,437 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate harness rework cost? Multiply the harnesses handled by the rework labor rate and the defect occurrence percentage, then add scrapped material. With 120 harnesses, $28/unit, 15% defects and $350 scrap, that is 120 x 28 x 0.15 + 350 = $854 total.
What is the rework cost per harness in this example? Divide the $854 total by the 120 harnesses reworked to get $7.12 per unit. That blended figure spreads the fixed $350 scrap across every harness, so it drops fast as volume rises.
What is the difference between variable and fixed rework cost here? The variable cost of $504 is the labor tied to the 15% that actually needed rework (120 x 28 x 0.15). The fixed $350 is scrapped material you eat regardless of how many units you rework.
What is a good harness rework cost per unit? There is no universal target, but on automotive and industrial harness lines a healthy program keeps rework under 2-4% of total build cost. If your per-unit rework rivals your per-unit build labor, the process is out of control.
How do I lower harness rework cost? Attack the defect occurrence first since it multiplies the labor term. Better crimp die maintenance, poka-yoke connector seating, and inline continuity testing cut the 15% far more effectively than shaving the labor rate.

Last reviewed 2026-05-12.