NPI, DFM/DFA & Engineering Change worked example

Pilot Run Cost at 58% chargeable pilot share: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop chargeable pilot share to 58%, then walk the calculation through step by step. Estimate the total cost of a pilot or pre-production run from pilot unit count, per-unit build cost, the chargeable share, and line setup cost.

The inputs for this scenario

  • Pilot units built: 60 units (held at the documented default)
  • Cost per pilot unit: 95 $ / unit (held at the documented default)
  • Chargeable pilot share: 58 % (the input this scenario stresses; the baseline uses 80)
  • Pilot line setup cost: 4,500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total pilot run cost = pilot units × cost per pilot unit × chargeable share + pilot line setup cost.
  • Total pilot run cost works out to 7,806 $ at these inputs, and this is the headline figure for the scenario.
  • Pilot run cost per unit works out to 130 $ / piece at these inputs.
  • Variable pilot run cost works out to 3,306 $ at these inputs.
  • Fixed pilot run cost adder works out to 4,500 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where chargeable pilot share sits at 80% and the headline result is 9,060 $, this scenario comes in 13.84% below the baseline at 7,806 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to chargeable pilot share, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a single per-unit cost; in real pilots the per-unit cost often falls as operators climb the learning curve mid-run.

Results at a glance

  • Total pilot run cost: 7,806 $ (headline result)
  • Pilot run cost per unit: 130 $ / piece
  • Variable pilot run cost: 3,306 $
  • Fixed pilot run cost adder: 4,500 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Pilot Run Cost calculator, set chargeable pilot share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.