Renewable Energy, Solar & Wind Manufacturing worked example

Inverter Assembly Cost at 65% burn-in pass rate: a worked example in renewable energy, solar & wind manufacturing

This worked example runs the inverter assembly cost numbers for a tougher week than the baseline: 65% burn-in pass rate instead of the typical 90%. Estimate inverter assembly cost from power-stage and labor spend per unit, burn-in pass rate and one-time test station setup.

The inputs for this scenario

  • Inverters Assembled: 150 units (held at the documented default)
  • Power Stage + Labor: 640 $/unit (held at the documented default)
  • Burn-In Pass Rate: 65 % (the input this scenario stresses; the baseline uses 90)
  • Test Station Setup: 5,000 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = inverters x (power stage + labor) x burn-in pass rate% + test setup.
  • Total inverter assembly cost works out to 67,400 $ at these inputs, and this is the headline figure for the scenario.
  • Inverter assembly cost per unit works out to 449 $ / piece at these inputs.
  • Variable inverter assembly cost works out to 62,400 $ at these inputs.
  • Fixed inverter assembly cost adder works out to 5,000 $ at these inputs.

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 26.26% below the baseline at 67,400 $.
  • Use it when quoting an inverter build, planning a burn-in cell, or comparing the cost impact of improving first-pass yield versus cutting BOM cost. 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 inverter assembly cost: 67,400 $ (headline result)
  • Inverter assembly cost per unit: 449 $ / piece
  • Variable inverter assembly cost: 62,400 $
  • Fixed inverter assembly cost adder: 5,000 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Inverter Assembly Cost calculator, set burn-in pass rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.