Pump, Compressor & Rotating Equipment Assembly worked example
Field Failure Cost at 58% share of failures attributable to assembly: a worked example in pump, compressor & rotating equipment assembly
This worked example runs the field failure cost numbers for a tougher week than the baseline: 58% share of failures attributable to assembly instead of the typical 80%. Field Failure Cost quantifies what warranty returns and in-service failures of assembled pumps, compressors, and rotating equipment actually cost your plant once you factor in per-unit repair spend, the share of failures your assembly line is responsible for, and the fixed dispatch overhead of getting a technician to a customer site.
The inputs for this scenario
- Pump/compressor units returned from field: 100 units (held at the documented default)
- Warranty repair cost per returned unit: 45 $ / unit (held at the documented default)
- Share of failures attributable to assembly: 58 % (the input this scenario stresses; the baseline uses 80)
- Fixed dispatch and logistics cost: 250 $ (held at the documented default)
Working through the calculation
- The calculation starts from the formula this tool documents: Field Failure Cost cost = quantity × rate × capture factor + fixed cost.
- Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
- Per piece value works out to 28.6 $ / piece at these inputs.
- Captured value works out to 2,610 $ at these inputs.
- Fixed adjustment works out to 250 $ at these inputs.
How this compares with the baseline
- Against the tool's baseline example, where share of failures attributable to assembly sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
- Use it when reviewing warranty claim data, quoting the cost of quality for a pump or compressor program, or building the business case for a balance or seal-installation process improvement. 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
- Weighted cost: 2,860 $ (headline result)
- Per piece value: 28.6 $ / piece
- Captured value: 2,610 $
- Fixed adjustment: 250 $
Run it with your numbers
- To rerun this with your own numbers, open the live Field Failure Cost calculator, set share of failures attributable to assembly to your actual value, and adjust the remaining inputs to match your operation.
Last reviewed 2026-05-12.