Weld Rejection Rate and Rework Cost Calculator

Calculate weld rejection rate, rework costs, and quality metrics for welding production tracking and improvement

Input Parameters

Results

--
Rejection Rate
%
--
Total Rework Cost
$
--
Total NDT + Rework Cost
$
--
Cost per Rejected Weld
$
Note: Industry benchmark rejection rates: Structural < 3%, Pressure vessel < 2%, Pipeline < 1.5%, Nuclear < 1%. Tracking rejection rates by welder, process, and joint type helps target improvement efforts.

Reference

Rejection Rate = (Rejected / Total) x 100% Rework Cost = Repair Labor + Re-inspection + Consumables Repair Labor = Rejected x Avg_Hours x Labor_Rate Consumables estimated at 15% of labor cost Industry target: < 2% rejection rate