Transformers, Coils & Magnetics Manufacturing worked example

Hi-Pot Test Capacity at 65% tester uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop tester uptime to 65%, then walk the calculation through step by step. Hi-pot test capacity tells a magnetics manufacturer how many coils or transformers can clear dielectric withstand (hi-pot) testing good per period, after tester uptime and first-pass pass rate.

The inputs for this scenario

  • Units tested per hi-pot cycle: 4 units / cycle (held at the documented default)
  • Hi-pot test cycles available in the period: 480 cycles (held at the documented default)
  • Tester uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Hi-pot first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross hi-pot test capacity capacity = units per cycle × available cycles.
  • Good output capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,920 units at these inputs.
  • Uptime loss works out to 672 units at these inputs.
  • Yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to tester uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats failures as removed from the good count; it does not model retest loops, which can recover borderline units but consume additional cycles.

Results at a glance

  • Good output capacity: 1,211 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 672 units
  • Yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Hi-Pot Test Capacity calculator, set tester uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.