Pharmaceutical Packaging & Serialization worked example

Blister Pack Yield at 68% target defect rate: a worked example

Suppose target defect rate falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate blister pack yield for pharmaceutical packaging and serialization using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.

The inputs for this scenario

  • Rejected or defective blister packs: 8 count (held at the documented default)
  • Total blister packs produced in the run: 250 count (held at the documented default)
  • Target defect (reject) rate: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Blister pack yield rate = blister pack yield count ÷ total blister pack yield population × 100.
  • Blister pack yield rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Blister pack yield gap to target works out to 64.8 points at these inputs.
  • Blister pack yield count works out to 8 count at these inputs.
  • Total blister pack yield population works out to 250 count at these inputs.

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 %.
  • It computes what percentage of the total blisters produced fell into the reject/defect count, and how far that percentage sits from your target rate. 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

  • Blister pack yield rate: 3.2 % (headline result)
  • Blister pack yield gap to target: 64.8 points
  • Blister pack yield count: 8 count
  • Total blister pack yield population: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Blister Pack Yield calculator, set target defect rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.