Single-Use Bioprocess Assemblies worked example

Kitting Completeness at 6.9% incomplete-kit rate: a worked example

Push incomplete-kit rate up to 6.9% and the picture changes. This example computes every intermediate figure at that operating point. A logistics planner quantifying the cost of missing connectors or clamps across a batch of single-use kits before shipping.

The inputs for this scenario

  • Kits Assembled: 800 kits (unchanged)
  • Shortage Recovery Cost: 55 $/kit (unchanged)
  • Incomplete-Kit Rate: 6.9 % (raised for this scenario; the documented default is 6)
  • BOM Audit Cost: 900 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Kitting completeness cost = kits assembled x shortage recovery cost x incomplete-kit rate + BOM audit cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,936 $ for total kitting completeness cost, the number this scenario is built around.
  • At this operating point the engine returns 4.92 $ / piece for kitting completeness cost per unit.
  • At this operating point the engine returns 3,036 $ for variable kitting completeness cost.
  • At this operating point the engine returns 900 $ for fixed kitting completeness adder.

How this compares with the baseline

  • Against the tool's baseline example, where incomplete-kit rate sits at 6% and the headline result is 3,540 $, this scenario comes in 11.19% above the baseline at 3,936 $.
  • It computes the total and per-kit cost of incomplete single-use kits from the volume of kits, the recovery cost per short kit, the incomplete-kit rate, and a fixed audit cost. 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 kitting completeness cost: 3,936 $ (headline result)
  • Kitting completeness cost per unit: 4.92 $ / piece
  • Variable kitting completeness cost: 3,036 $
  • Fixed kitting completeness adder: 900 $

Run it with your numbers

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

Last reviewed 2026-05-12.