Electronics Manufacturing worked example

Functional Test Cost with assemblies functionally tested of 3,000 assemblies: a worked example

This scenario runs the functional test cost calculation on the strong side: assemblies functionally tested of 3,000 assemblies, with every other input held at its documented default. an estimator or test engineer needs a functional test cost for an assembly quote

The inputs for this scenario

  • Assemblies functionally tested: 3,000 assemblies (raised for this scenario; the documented default is 1,200)
  • Variable functional test cost: 1.75 $ / assembly (unchanged)
  • Functional test labor or setup cost: 360 $ (unchanged)
  • Fixture, software, and overhead cost: 240 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total functional test cost = assemblies functionally tested × variable functional test cost + labor/setup + overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,850 $ for total functional test cost, the number this scenario is built around.
  • At this operating point the engine returns 1.95 $ / assembly for functional test cost per assembly.
  • At this operating point the engine returns 5,250 $ for variable functional test cost.
  • At this operating point the engine returns 600 $ for test labor, fixture, and overhead adders.

How this compares with the baseline

  • Against the tool's baseline example, where assemblies functionally tested sits at 1,200 assemblies and the headline result is 2,700 $, this scenario comes in 117% above the baseline at 5,850 $.
  • Use it when quoting a job, comparing test approaches, or amortizing fixture and software cost over a production run. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total functional test cost: 5,850 $ (headline result)
  • Functional test cost per assembly: 1.95 $ / assembly
  • Variable functional test cost: 5,250 $
  • Test labor, fixture, and overhead adders: 600 $

Run it with your numbers

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

Last reviewed 2026-05-12.