Semiconductor Advanced Packaging & Test worked example

Package Test Cost at 99% first-pass test coverage: a worked example

What does the result look like when first-pass test coverage reaches 99%? The full calculation is worked below with real intermediate numbers. Use it to weigh tester time, first-pass yield, and program setup when quoting a package test flow.

The inputs for this scenario

  • Devices tested at final test: 50,000 units (unchanged)
  • Tester cost per second of insertion: 0.28 $/unit (unchanged)
  • First-pass test coverage: 99 % (raised for this scenario; the documented default is 92)
  • Test program and load-board setup: 8,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = devices x tester cost per insertion x first-pass% + setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 21,860 $ for total package test cost, the number this scenario is built around.
  • At this operating point the engine returns 0.44 $ / piece for package test cost per unit.
  • At this operating point the engine returns 13,860 $ for variable package test cost.
  • At this operating point the engine returns 8,000 $ for fixed package test cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass test coverage sits at 92% and the headline result is 20,880 $, this scenario comes in 4.69% above the baseline at 21,860 $.
  • A figure at this level is achievable when first-pass test coverage is genuinely sustained, not just peaked for a shift. It uses a flat first-pass coverage and single insertion rate, so it won't model retest loops, multi-site parallelism savings, or binning that changes effective per-good cost.

Results at a glance

  • Total package test cost: 21,860 $ (headline result)
  • Package test cost per unit: 0.44 $ / piece
  • Variable package test cost: 13,860 $
  • Fixed package test cost adder: 8,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.