Wire Harness, Cable & Electromechanical Assembly worked example

Terminal Cost at 69% crimp first-pass yield: a worked example

Suppose crimp first-pass yield falls to 69%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the cost of crimped terminals on a harness including terminal piece price, crimp cycle and applicator setup.

The inputs for this scenario

  • Number of terminations: 120 crimps (held at the documented default)
  • Terminal price per crimp: 0.14 $/crimp (held at the documented default)
  • Crimp first-pass yield: 69 % (the input this scenario stresses; the baseline uses 96)
  • Applicator setup charge: 45 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = terminations x cost per termination x crimp first-pass yield% + applicator setup charge.
  • Total terminal cost works out to 56.59 $ at these inputs, and this is the headline figure for the scenario.
  • Terminal cost per unit works out to 0.47 $ / piece at these inputs.
  • Variable terminal cost works out to 11.59 $ at these inputs.
  • Fixed terminal cost adder works out to 45 $ at these inputs.

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 7.42% below the baseline at 56.59 $.
  • 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. 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 terminal cost: 56.59 $ (headline result)
  • Terminal cost per unit: 0.47 $ / piece
  • Variable terminal cost: 11.59 $
  • Fixed terminal cost adder: 45 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Terminal Cost calculator, set crimp first-pass yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.