Renewable Energy, Solar & Wind Manufacturing worked example

Inverter Assembly Cost at 99% burn-in pass rate: a worked example in renewable energy, solar & wind manufacturing

Push burn-in pass rate up to 99% and the picture changes. This example computes every intermediate figure at that operating point. A power-electronics line planner uses it to combine IGBT or SiC stage cost, build labor and burn-in yield into a per-inverter assembly cost.

The inputs for this scenario

  • Inverters Assembled: 150 units (unchanged)
  • Power Stage + Labor: 640 $/unit (unchanged)
  • Burn-In Pass Rate: 99 % (raised for this scenario; the documented default is 90)
  • Test Station Setup: 5,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = inverters x (power stage + labor) x burn-in pass rate% + test setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 100,040 $ for total inverter assembly cost, the number this scenario is built around.
  • At this operating point the engine returns 667 $ / piece for inverter assembly cost per unit.
  • At this operating point the engine returns 95,040 $ for variable inverter assembly cost.
  • At this operating point the engine returns 5,000 $ for fixed inverter assembly cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where burn-in pass rate sits at 90% and the headline result is 91,400 $, this scenario comes in 9.45% above the baseline at 100,040 $.
  • It multiplies inverters assembled by the combined power-stage-plus-labor rate, scales that variable cost by the burn-in pass rate, then adds a fixed test-station setup charge and divides for per-unit cost. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total inverter assembly cost: 100,040 $ (headline result)
  • Inverter assembly cost per unit: 667 $ / piece
  • Variable inverter assembly cost: 95,040 $
  • Fixed inverter assembly cost adder: 5,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.