Electronics Manufacturing worked example

AOI False Call Cost at 72% false-call population in scope: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop false-call population in scope to 72%, then walk the calculation through step by step. Estimate the cost of AOI false calls from review count, loaded review cost, occurrence share, and fixed disposition support.

The inputs for this scenario

  • AOI false calls reviewed: 420 calls (held at the documented default)
  • Cost per false-call review: 1.85 $ / call (held at the documented default)
  • False-call population in scope: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed AOI tuning or disposition cost: 150 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable false-call review cost = AOI false calls reviewed × cost per false-call review × false-call population in scope.
  • Total AOI false-call cost works out to 709 $ at these inputs, and this is the headline figure for the scenario.
  • AOI false-call cost per call works out to 1.69 $ / call at these inputs.
  • Variable false-call review cost works out to 559 $ at these inputs.
  • Fixed AOI tuning or disposition cost works out to 150 $ at these inputs.

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 23.47% below the baseline at 709 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to false-call population in scope, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 709 $ (headline result)
  • AOI false-call cost per call: 1.69 $ / call
  • Variable false-call review cost: 559 $
  • Fixed AOI tuning or disposition cost: 150 $

Run it with your numbers

  • To rerun this with your own numbers, open the live AOI False Call Cost calculator, set false-call population in scope to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.