UAV & Drone Manufacturing worked example

Pack-Out Completeness at 70% complete-kit first-pass audit rate: a worked example

This worked example runs the pack-out completeness numbers for a tougher week than the baseline: 70% complete-kit first-pass audit rate instead of the typical 97%. Estimate the cost of fully kitting, verifying, and crating finished drones so every shipped box leaves the line complete.

The inputs for this scenario

  • Shippable airframes in the run: 240 units (held at the documented default)
  • Kitting, foam and crate cost per airframe: 62 $ / unit (held at the documented default)
  • Complete-kit first-pass audit rate: 70 % (the input this scenario stresses; the baseline uses 97)
  • Line audit and label-setup fixed cost: 850 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Pack-out completeness cost = shippable airframes x kitting and crate cost per airframe x complete-kit pass rate + line audit and label setup cost.
  • Total pack-out completeness cost works out to 11,266 $ at these inputs, and this is the headline figure for the scenario.
  • Pack-out completeness cost per unit works out to 46.94 $ / piece at these inputs.
  • Variable pack-out completeness cost works out to 10,416 $ at these inputs.
  • Fixed pack-out completeness adder works out to 850 $ at these inputs.

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 26.29% below the baseline at 11,266 $.
  • Use it when quoting fulfillment cost for a build lot or deciding whether a barcode-verified pack-out line pays for itself. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total pack-out completeness cost: 11,266 $ (headline result)
  • Pack-out completeness cost per unit: 46.94 $ / piece
  • Variable pack-out completeness cost: 10,416 $
  • Fixed pack-out completeness adder: 850 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Pack-Out Completeness calculator, set complete-kit first-pass audit rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.