Rework and Accepted Output

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Minitab’s yield explanation excludes repaired units from first-pass throughput. Final output can conceal rework.

Follow one completed batch

Fictional batch starts with 800 units. Stage one passes 760 without rework: 95%. Only those 760 enter stage two, where 684 pass without rework: 90%.

End-to-end first-pass yield is 95% × 90% = 85.5%, matching 684 ÷ 800. Stage percentages use different entering quantities; do not average them.

Later, 60 distinct units from the 116 rejected units are repaired and pass all required checks. Final accepted output is 684 + 60 = 744 units, or 93%. The remaining 56 are scrapped with no recovery value.

Cost accepted output

Assume initial batch cash spending of $6,840 plus $600 additional rework spending, with no other costs or recoveries. Total is $7,440; divided by 744 accepted units, that is $10 each.

The 93% final yield does not erase rework. Keep original passes, recovered units and added spending separate. This completed-batch cash average is neither an inventory-accounting policy nor a production forecast.