Rework Cost Calculator A part you can save still ships, so it is NOT grossed up like scrap - only the repair effort is added. Type your repair rate and cost per repair into the current-state table, then the improved figures into the optimized one; the saving percentage falls out on its own. Nothing is saved unless you want it to be.
Overall Impact Realtime Total BEFORE?
not filled in
Total AFTER?
not filled in
SAVINGS?
OPTIMIZED table is empty — nothing to compare yet
An empty table does not mean zero — the system will not read it as a 100% saving.
COST BY CATEGORY
Labor? 0 USD
Machine? 0 USD
Material? 0 USD
Scrap? 0 USD
Consumable? 0 USD
Outsourced processing? 0 USD
Rework? 0 USD
Packaging? 0 USD
Logistics? 0 USD
Factory overhead? 0 USD
Done calculating? Turn it into a real case to save it and compare with your industry.
Write a case from this data Not sure where the numbers come from? What the system reads in your figures 1 Efficiency is set to 1.0 (100%) — this is the DEFAULT starting value, not a number you confirmed. 100% means nobody rests, nothing waits for materials, no changeovers happen all month. Ohno ("Toyota Production System"): "the ideal rate is not necessarily 100 percent" - running flat out raises the odds of breakdowns. Update it if you know the real figure for your plant; if not, leaving it is fine too — this is just a nudge to check.