Wire Harness, Cable & Electromechanical Assembly worked example

Connector Cost at 99% connector yield: a worked example

This scenario runs the connector cost calculation on the strong side: 99% connector yield, with every other input held at its documented default. Use it when connector housings drive the bill of material and you need to capture loading labor and pin-position rework.

The inputs for this scenario

  • Connectors Loaded: 60 connectors (unchanged)
  • Cost per Connector: 2.4 $/connector (unchanged)
  • Connector Yield: 99 % (raised for this scenario; the documented default is 94)
  • Tooling and Test Adder: 75 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = connectors loaded x cost per connector x connector yield% + tooling and test adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 218 $ for total connector cost, the number this scenario is built around.
  • At this operating point the engine returns 3.63 $ / piece for connector cost per unit.
  • At this operating point the engine returns 143 $ for variable connector cost.
  • At this operating point the engine returns 75 $ for fixed connector cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where connector yield sits at 94% and the headline result is 210 $, this scenario comes in 3.42% above the baseline at 218 $.
  • Use it when quoting a new harness, comparing connector suppliers, or validating a costed BOM before you commit to a program price. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total connector cost: 218 $ (headline result)
  • Connector cost per unit: 3.63 $ / piece
  • Variable connector cost: 143 $
  • Fixed connector cost adder: 75 $

Run it with your numbers

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

Last reviewed 2026-05-12.