Consumer Goods & Durable Products Manufacturing worked example

Drop Test Failure Cost at 110% drop-test failure scope included: a worked example

What does the result look like when drop-test failure scope included reaches 110%? The full calculation is worked below with real intermediate numbers. deciding whether packaging reinforcement, product protection, or additional validation is worth the cost

The inputs for this scenario

  • Failed drop-test samples or affected SKUs: 18 samples (unchanged)
  • Cost per failed packaged-product test: 420 $ / sample (unchanged)
  • Drop-test failure scope included: 110 % (raised for this scenario; the documented default is 100)
  • Fixed packaging redesign and retest cost: 5,600 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable drop-test failure cost = failed drop-test samples or affected SKUs × cost per failed packaged-product test × drop-test failure scope included) to the inputs above produces each figure below.
  • At this operating point the engine returns 13,916 $ for total drop-test failure cost, the number this scenario is built around.
  • At this operating point the engine returns 773 $ / piece for drop-test failure cost per sample or sku.
  • At this operating point the engine returns 8,316 $ for variable drop-test failure cost.
  • At this operating point the engine returns 5,600 $ for fixed packaging redesign and retest cost.

How this compares with the baseline

  • Against the tool's baseline example, where drop-test failure scope included sits at 100% and the headline result is 13,160 $, this scenario comes in 5.74% above the baseline at 13,916 $.
  • A figure at this level is achievable when drop-test failure scope included is genuinely sustained, not just peaked for a shift. It treats per-sample failure cost as uniform and counts one redesign cycle, so a problem requiring multiple redesign-retest loops or scrapped finished goods needs those rounds added separately.

Results at a glance

  • total drop-test failure cost: 13,916 $ (headline result)
  • drop-test failure cost per sample or SKU: 773 $ / piece
  • variable drop-test failure cost: 8,316 $
  • fixed packaging redesign and retest cost: 5,600 $

Run it with your numbers

  • Every input above is editable in the live Drop Test Failure Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.