Wire Harness, Cable & Electromechanical Assembly worked example

Electromechanical Assembly Cost at 99% first-pass yield: a worked example

What does the result look like when first-pass yield reaches 99%? The full calculation is worked below with real intermediate numbers. An assembly house quoting a connectorized motor-and-bracket subassembly uses it to roll labor, parts and fixture setup into a defensible unit price.

The inputs for this scenario

  • Assemblies Built: 250 units (unchanged)
  • Labor + Component Rate: 85 $/unit (unchanged)
  • First-Pass Yield: 99 % (raised for this scenario; the documented default is 92)
  • Tooling & Fixture Setup: 1,800 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = assemblies x (labor + component rate) x first-pass yield% + tooling setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 22,838 $ for total electromechanical assembly cost, the number this scenario is built around.
  • At this operating point the engine returns 91.35 $ / piece for electromechanical assembly cost per unit.
  • At this operating point the engine returns 21,038 $ for variable electromechanical assembly cost.
  • At this operating point the engine returns 1,800 $ for fixed electromechanical assembly cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass yield sits at 92% and the headline result is 21,350 $, this scenario comes in 6.97% above the baseline at 22,838 $.
  • A figure at this level is achievable when first-pass yield is genuinely sustained, not just peaked for a shift. The single blended labor+component rate hides which of the two is driving cost, so it will not tell you whether a price increase came from copper, connectors, or slower cycle times.

Results at a glance

  • Total electromechanical assembly cost: 22,838 $ (headline result)
  • Electromechanical assembly cost per unit: 91.35 $ / piece
  • Variable electromechanical assembly cost: 21,038 $
  • Fixed electromechanical assembly cost adder: 1,800 $

Run it with your numbers

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

Last reviewed 2026-05-12.