Electronics Manufacturing worked example

Functional Test Cost with assemblies functionally tested of 600 assemblies: a worked example

This worked example runs the functional test cost numbers for a tougher week than the baseline: assemblies functionally tested of 600 assemblies instead of the typical 1,200 assemblies. Estimate functional test cost for electronic assemblies from tested units, variable test cost, labor/setup cost, and overhead.

The inputs for this scenario

  • Assemblies functionally tested: 600 assemblies (the input this scenario stresses; the baseline uses 1,200)
  • Variable functional test cost: 1.75 $ / assembly (held at the documented default)
  • Functional test labor or setup cost: 360 $ (held at the documented default)
  • Fixture, software, and overhead cost: 240 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total functional test cost = assemblies functionally tested × variable functional test cost + labor/setup + overhead.
  • Total functional test cost works out to 1,650 $ at these inputs, and this is the headline figure for the scenario.
  • Functional test cost per assembly works out to 2.75 $ / assembly at these inputs.
  • Variable functional test cost works out to 1,050 $ at these inputs.
  • Test labor, fixture, and overhead adders works out to 600 $ at these inputs.

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 38.89% below the baseline at 1,650 $.
  • Use it when quoting a job, comparing test approaches, or amortizing fixture and software cost over a production run. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total functional test cost: 1,650 $ (headline result)
  • Functional test cost per assembly: 2.75 $ / assembly
  • Variable functional test cost: 1,050 $
  • Test labor, fixture, and overhead adders: 600 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Functional Test Cost calculator, set assemblies functionally tested to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.