Semiconductor Advanced Packaging & Test worked example

Test Escape Cost at 1% defect escape rate: a worked example

Suppose defect escape rate falls to 1%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimates the cost of defective devices that escape final test and reach the customer.

The inputs for this scenario

  • Units shipped to customer: 200,000 units (held at the documented default)
  • Cost of one escaped defect: 18 $/unit (held at the documented default)
  • Defect escape rate: 1 % (the input this scenario stresses; the baseline uses 0.3)
  • Containment and 8D overhead: 15,000 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = units shipped x cost per escape x escape rate% + containment overhead.
  • Total test escape cost works out to 51,000 $ at these inputs, and this is the headline figure for the scenario.
  • Test escape cost per unit works out to 0.26 $ / piece at these inputs.
  • Variable test escape cost works out to 36,000 $ at these inputs.
  • Fixed test escape cost adder works out to 15,000 $ at these inputs.

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 97.67% above the baseline at 51,000 $.
  • It computes the total and per-shipped-unit cost of defects that escaped final test, including variable escape cost plus fixed containment and 8D overhead. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total test escape cost: 51,000 $ (headline result)
  • Test escape cost per unit: 0.26 $ / piece
  • Variable test escape cost: 36,000 $
  • Fixed test escape cost adder: 15,000 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Test Escape Cost calculator, set defect escape rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.