Pharmaceutical Packaging & Serialization worked example

Blister Pack Yield at 99% target defect rate: a worked example

What does the result look like when target defect rate reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when blister pack yield in pharmaceutical packaging and serialization needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Rejected or defective blister packs: 8 count (unchanged)
  • Total blister packs produced in the run: 250 count (unchanged)
  • Target defect (reject) rate: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Blister pack yield rate = blister pack yield count ÷ total blister pack yield population × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 % for blister pack yield rate, the number this scenario is built around.
  • At this operating point the engine returns 95.8 points for blister pack yield gap to target.
  • At this operating point the engine returns 8 count for blister pack yield count.
  • At this operating point the engine returns 250 count for total blister pack yield population.

How this compares with the baseline

  • Against the tool's baseline example, where target defect rate sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • A figure at this level is achievable when target defect rate is genuinely sustained, not just peaked for a shift. With this field mapping the output is a reject rate, not a good-yield rate — a low number is good and a high number is bad, which is the opposite of a typical yield reading, so read the sign of the gap carefully.

Results at a glance

  • Blister pack yield rate: 3.2 % (headline result)
  • Blister pack yield gap to target: 95.8 points
  • Blister pack yield count: 8 count
  • Total blister pack yield population: 250 count

Run it with your numbers

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

Last reviewed 2026-05-12.