Internal Rework, Your Days Are Numbered

Foreign material contamination can do a number on your bottom line—no matter how comprehensive your HACCP plan may be. Finding an efficient, cost-effective method that solves your product holds every time is critical to maximizing your ROI and reducing waste at the plant level.

Manufacturers often opt to internally rework their product in the face of foreign material contamination. In a recent blog post, we “covered the costs” of that option at a broad level. While that piece is by no means exhaustive, we believe it summarizes the key considerations for manufacturers well. If you haven’t already read that, we encourage you to do so!

While we firmly believe that rework should be a tool of the past, we understand that you need to weigh your options. Below, we’ve created a resource that allows you to calculate the base cost of internal rework for your current product hold.

Cost of Labor

The cost of using your internal labor resources to rework your product:
Number of Employees x Avg. Hourly Rate x Number of Hours

Product Value

The value of the product you’d throw away if rework doesn’t work, in units:
Units of Product x $ Value per Unit

Time Loss

The amount of time you’d lose shutting down product to rework product:
Avg. Product Units x $ Value per Unit x Number of Hours


The calculator tool above doesn’t cover the entire cost of internal rework—without more specifics, it can’t. The total cost you see there is only the minimum effect internal rework could have on your bottom line. At the very least, we hope seeing that number gave you pause. 

Our bottom line is to protect yours. The best way to achieve that goal is by putting FlexXray’s third-party inspection and retrieval services to work. If you send us a test sample, we have inspection lines available now to put our customized, medical-grade machinery where our mouth is. To continue the conversation, talk to our team today!

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