Consumer Goods & Durable Products Manufacturing worked example

Drop Test Failure Cost at 72% drop-test failure scope included: a worked example

Suppose drop-test failure scope included falls to 72%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the cost exposure from failed packaged-product drop tests.

The inputs for this scenario

  • Failed drop-test samples or affected SKUs: 18 samples (held at the documented default)
  • Cost per failed packaged-product test: 420 $ / sample (held at the documented default)
  • Drop-test failure scope included: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed packaging redesign and retest cost: 5,600 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable drop-test failure cost = failed drop-test samples or affected SKUs × cost per failed packaged-product test × drop-test failure scope included.
  • total drop-test failure cost works out to 11,043 $ at these inputs, and this is the headline figure for the scenario.
  • drop-test failure cost per sample or SKU works out to 614 $ / piece at these inputs.
  • variable drop-test failure cost works out to 5,443 $ at these inputs.
  • fixed packaging redesign and retest cost works out to 5,600 $ at these inputs.

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 16.09% below the baseline at 11,043 $.
  • It computes total drop-test failure cost and cost per sample by adding scaled per-sample failure cost to the fixed packaging redesign and retest spend. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • total drop-test failure cost: 11,043 $ (headline result)
  • drop-test failure cost per sample or SKU: 614 $ / piece
  • variable drop-test failure cost: 5,443 $
  • fixed packaging redesign and retest cost: 5,600 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Drop Test Failure Cost calculator, set drop-test failure scope included to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.