Wire Harness, Cable & Electromechanical Assembly worked example

Connector Cost at 68% connector yield: a worked example

Suppose connector yield falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate connector content cost on a harness including housing piece price, contact loading and test fixturing.

The inputs for this scenario

  • Connectors Loaded: 60 connectors (held at the documented default)
  • Cost per Connector: 2.4 $/connector (held at the documented default)
  • Connector Yield: 68 % (the input this scenario stresses; the baseline uses 94)
  • Tooling and Test Adder: 75 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = connectors loaded x cost per connector x connector yield% + tooling and test adder.
  • Total connector cost works out to 173 $ at these inputs, and this is the headline figure for the scenario.
  • Connector cost per unit works out to 2.88 $ / piece at these inputs.
  • Variable connector cost works out to 97.92 $ at these inputs.
  • Fixed connector cost adder works out to 75 $ at these inputs.

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 17.8% below the baseline at 173 $.
  • It computes total connector spend for a harness (price times count adjusted for yield, plus a fixed tooling and test adder) and the resulting cost per connector loaded. 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

  • Total connector cost: 173 $ (headline result)
  • Connector cost per unit: 2.88 $ / piece
  • Variable connector cost: 97.92 $
  • Fixed connector cost adder: 75 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Connector Cost calculator, set connector yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.