UAV & Drone Manufacturing worked example

Pack-Out Completeness at 99% complete-kit first-pass audit rate: a worked example

What does the result look like when complete-kit first-pass audit rate reaches 99%? The full calculation is worked below with real intermediate numbers. you need to price the final accessory-kit and crate step for a drone build batch and confirm boxes ship without missing props, batteries, or documents.

The inputs for this scenario

  • Shippable airframes in the run: 240 units (unchanged)
  • Kitting, foam and crate cost per airframe: 62 $ / unit (unchanged)
  • Complete-kit first-pass audit rate: 99 % (raised for this scenario; the documented default is 97)
  • Line audit and label-setup fixed cost: 850 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Pack-out completeness cost = shippable airframes x kitting and crate cost per airframe x complete-kit pass rate + line audit and label setup cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 15,581 $ for total pack-out completeness cost, the number this scenario is built around.
  • At this operating point the engine returns 64.92 $ / piece for pack-out completeness cost per unit.
  • At this operating point the engine returns 14,731 $ for variable pack-out completeness cost.
  • At this operating point the engine returns 850 $ for fixed pack-out completeness adder.

How this compares with the baseline

  • Against the tool's baseline example, where complete-kit first-pass audit rate sits at 97% and the headline result is 15,284 $, this scenario comes in 1.95% above the baseline at 15,581 $.
  • A figure at this level is achievable when complete-kit first-pass audit rate is genuinely sustained, not just peaked for a shift. The pass-rate weighting models expected complete-kit cost, not the downstream cost of the shipments that go out incomplete — track RMA cost separately.

Results at a glance

  • Total pack-out completeness cost: 15,581 $ (headline result)
  • Pack-out completeness cost per unit: 64.92 $ / piece
  • Variable pack-out completeness cost: 14,731 $
  • Fixed pack-out completeness adder: 850 $

Run it with your numbers

  • Every input above is editable in the live Pack-Out Completeness calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.