Transformers, Coils & Magnetics Manufacturing worked example

Test Failure Cost at 58% test capture rate: a worked example

Suppose test capture rate falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Test failure cost quantifies what final electrical testing of transformers and coils really costs when you account for how many units fail, the rework or scrap cost each carries, how effectively the test catches defects, and the fixed cost of the test setup.

The inputs for this scenario

  • Units tested in batch: 100 units (held at the documented default)
  • Cost per failed unit: 45 $ / unit (held at the documented default)
  • Test capture rate: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed test setup cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Test Failure Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • It multiplies tested quantity by cost per failed unit and the capture rate, adds the fixed test cost, and also divides the total by quantity for a per-unit figure. 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

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.