Semiconductor Advanced Packaging & Test worked example

Test Escape Cost at 0.35% defect escape rate: a worked example

This scenario runs the test escape cost calculation on the strong side: 0.35% defect escape rate, with every other input held at its documented default. Use it to price test-escape risk and justify added test coverage or burn-in on a package flow.

The inputs for this scenario

  • Units shipped to customer: 200,000 units (unchanged)
  • Cost of one escaped defect: 18 $/unit (unchanged)
  • Defect escape rate: 0.35 % (raised for this scenario; the documented default is 0.3)
  • Containment and 8D overhead: 15,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = units shipped x cost per escape x escape rate% + containment overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 27,600 $ for total test escape cost, the number this scenario is built around.
  • At this operating point the engine returns 0.14 $ / piece for test escape cost per unit.
  • At this operating point the engine returns 12,600 $ for variable test escape cost.
  • At this operating point the engine returns 15,000 $ for fixed test escape cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where defect escape rate sits at 0.3% and the headline result is 25,800 $, this scenario comes in 6.98% above the baseline at 27,600 $.
  • Use it when setting DPPM targets, evaluating whether to add a test insertion or tighten a guardband, or building the cost case in an 8D corrective action. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total test escape cost: 27,600 $ (headline result)
  • Test escape cost per unit: 0.14 $ / piece
  • Variable test escape cost: 12,600 $
  • Fixed test escape cost adder: 15,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.