Wearable Medical Sensors worked example

Field Failure Cost at 63% events triggering full response: a worked example in wearable medical sensors

Push events triggering full response up to 63% and the picture changes. This example computes every intermediate figure at that operating point. A quality manager quantifying the financial exposure of in-use sensor failures for a quarterly review.

The inputs for this scenario

  • Field Failure Events: 320 events (unchanged)
  • Cost to Resolve One Failure: 145 $ / event (unchanged)
  • Events Triggering Full Response: 63 % (raised for this scenario; the documented default is 55)
  • Complaint Handling Infrastructure: 6,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Field failure cost = failure events x cost per event x (% full response) + infrastructure) to the inputs above produces each figure below.
  • At this operating point the engine returns 35,232 $ for total field failure cost, the number this scenario is built around.
  • At this operating point the engine returns 110 $ / piece for field failure cost per unit.
  • At this operating point the engine returns 29,232 $ for variable field failure cost.
  • At this operating point the engine returns 6,000 $ for fixed field failure cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where events triggering full response sits at 55% and the headline result is 31,520 $, this scenario comes in 11.78% above the baseline at 35,232 $.
  • It computes total field failure cost and cost per event by applying the per-event resolution cost weighted by the escalation share, then adding fixed complaint-handling infrastructure. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total field failure cost: 35,232 $ (headline result)
  • Field failure cost per unit: 110 $ / piece
  • Variable field failure cost: 29,232 $
  • Fixed field failure cost adder: 6,000 $

Run it with your numbers

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

Last reviewed 2026-05-12.