Transformers, Coils & Magnetics Manufacturing worked example

Hi-Pot Test Capacity at 99% tester uptime: a worked example

Push tester uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when hi-pot test capacity in transformers, coils and magnetics manufacturing is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Units tested per hi-pot cycle: 4 units / cycle (unchanged)
  • Hi-pot test cycles available in the period: 480 cycles (unchanged)
  • Tester uptime: 99 % (raised for this scenario; the documented default is 90)
  • Hi-pot first-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross hi-pot test capacity capacity = units per cycle × available cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross capacity.
  • At this operating point the engine returns 19.2 units for uptime loss.
  • At this operating point the engine returns 57.02 units for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where tester uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It computes good units cleared through hi-pot testing from units per cycle, available cycles, tester uptime, and first-pass pass rate. 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

  • Good output capacity: 1,844 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 19.2 units
  • Yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Hi-Pot Test Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.