Electronics Manufacturing worked example

AOI False Call Cost at 110% false-call population in scope: a worked example

What does the result look like when false-call population in scope reaches 110%? The full calculation is worked below with real intermediate numbers. a quality engineer is deciding whether AOI program tuning is worth the effort

The inputs for this scenario

  • AOI false calls reviewed: 420 calls (unchanged)
  • Cost per false-call review: 1.85 $ / call (unchanged)
  • False-call population in scope: 110 % (raised for this scenario; the documented default is 100)
  • Fixed AOI tuning or disposition cost: 150 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable false-call review cost = AOI false calls reviewed × cost per false-call review × false-call population in scope) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,005 $ for total aoi false-call cost, the number this scenario is built around.
  • At this operating point the engine returns 2.39 $ / call for aoi false-call cost per call.
  • At this operating point the engine returns 855 $ for variable false-call review cost.
  • At this operating point the engine returns 150 $ for fixed aoi tuning or disposition cost.

How this compares with the baseline

  • Against the tool's baseline example, where false-call population in scope sits at 100% and the headline result is 927 $, this scenario comes in 8.38% above the baseline at 1,005 $.
  • A figure at this level is achievable when false-call population in scope is genuinely sustained, not just peaked for a shift. It values only direct review labor and a flat fixed cost; it does not capture throughput loss, operator fatigue, or the risk of escapes when verifiers rubber-stamp calls.

Results at a glance

  • Total AOI false-call cost: 1,005 $ (headline result)
  • AOI false-call cost per call: 2.39 $ / call
  • Variable false-call review cost: 855 $
  • Fixed AOI tuning or disposition cost: 150 $

Run it with your numbers

  • Every input above is editable in the live AOI False Call Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.