Transformers, Coils & Magnetics Manufacturing worked example

Test Failure Cost at 92% test capture rate: a worked example

What does the result look like when test capture rate reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when test failure cost in transformers, coils and magnetics manufacturing is being put through a transformers, coils and magnetics manufacturing weighted-cost review.

The inputs for this scenario

  • Units tested in batch: 100 units (unchanged)
  • Cost per failed unit: 45 $ / unit (unchanged)
  • Test capture rate: 92 % (raised for this scenario; the documented default is 80)
  • Fixed test setup cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Test Failure Cost cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where test capture rate sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when test capture rate is genuinely sustained, not just peaked for a shift. It models the capture rate as a flat multiplier on cost and does not separately value escaped defects that reach the field, which usually cost far more than in-house catches.

Results at a glance

  • Weighted cost: 4,390 $ (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.