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How much rework is hiding behind acceptable final yield?
Calculate labor effort released by improving first-pass quality.
Example scenario
Editable demonstration inputs, not verified industry benchmarks. Enable JavaScript to calculate your own scenario.
- Annual units inspected
- 100,000
- Current first-pass yield
- 85 %
- Target first-pass yield
- 93 %
- Average rework minutes / failed first pass
- 20
- Loaded rework labor cost / hour
- $45
- Released labor cost actually avoidable
- 30 %
- Annual quality program cost
- $20,000
Annual avoidable rework cost net of program
Example result only, not a forecast or promise.
- Rework hours released
- 2,666.7
- Total labor time value
- $120,000
- Cash-avoidable labor savings
- $36,000
What to do with this result
Track rework touches and quality escapes; show redeployed hours separately from payroll reductions.
Know what is inside the model.
Planning model, not personalized financial advice. Your inputs remain in your browser.
Calculation method
Rework hours released = units × change in first-pass yield × rework minutes / 60. Avoidable labor savings = released hours × hourly cost × cash-avoidable share.
Assumptions and limitations
- Example inputs are editable scenarios, not Aryo results or independently verified industry benchmarks.
- Recovered capacity is not booked revenue or automatic cash savings. Validate the bottleneck, quality and demand before monetizing output.