Wire Harness, Cable & Electromechanical Assembly worked example

Terminal Cost at 99% crimp first-pass yield: a worked example

Push crimp first-pass yield up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when a job has high termination counts and you need to capture both the per-crimp cost and the applicator changeover.

The inputs for this scenario

  • Number of terminations: 120 crimps (unchanged)
  • Terminal price per crimp: 0.14 $/crimp (unchanged)
  • Crimp first-pass yield: 99 % (raised for this scenario; the documented default is 96)
  • Applicator setup charge: 45 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = terminations x cost per termination x crimp first-pass yield% + applicator setup charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 61.63 $ for total terminal cost, the number this scenario is built around.
  • At this operating point the engine returns 0.51 $ / piece for terminal cost per unit.
  • At this operating point the engine returns 16.63 $ for variable terminal cost.
  • At this operating point the engine returns 45 $ for fixed terminal cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where crimp first-pass yield sits at 96% and the headline result is 61.13 $, this scenario comes in 0.82% above the baseline at 61.63 $.
  • It computes total terminal cost as terminations times unit price times first-pass yield plus a setup charge, and divides by count for cost per termination. 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 terminal cost: 61.63 $ (headline result)
  • Terminal cost per unit: 0.51 $ / piece
  • Variable terminal cost: 16.63 $
  • Fixed terminal cost adder: 45 $

Run it with your numbers

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

Last reviewed 2026-05-12.