Wire Harness, Cable & Electromechanical Assembly worked example

Pull Test Sample Size at 99% pull tester uptime: a worked example

What does the result look like when pull tester uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when pull test sample size in wire harness, cable and electromechanical assembly is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Terminations Pulled per Cycle: 4 units / cycle (unchanged)
  • Available Pull-Test Cycles: 480 cycles (unchanged)
  • Pull Tester Uptime: 99 % (raised for this scenario; the documented default is 90)
  • Termination First-Pass Yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross pull test sample size capacity = pull test sample size output per cycle × available pull test sample size cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good pull test sample size capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross pull test sample size capacity.
  • At this operating point the engine returns 19.2 units for pull test sample size downtime loss.
  • At this operating point the engine returns 57.02 units for pull test sample size yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where pull tester uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when pull tester uptime is genuinely sustained, not just peaked for a shift. It treats uptime and yield as independent flat rates, so it will not model a bad crimp die that raises failures and jams the tester at once.

Results at a glance

  • Good pull test sample size capacity: 1,844 units (headline result)
  • Gross pull test sample size capacity: 1,920 units
  • Pull test sample size downtime loss: 19.2 units
  • Pull test sample size yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Pull Test Sample Size calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.