Single-Use Bioprocess Assemblies worked example

Kitting Completeness at 4.32% incomplete-kit rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop incomplete-kit rate to 4.32%, then walk the calculation through step by step. Estimate the cost of kitting incompleteness for single-use bioprocess kits from shortage recovery cost, incomplete-kit rate, and BOM audit.

The inputs for this scenario

  • Kits Assembled: 800 kits (held at the documented default)
  • Shortage Recovery Cost: 55 $/kit (held at the documented default)
  • Incomplete-Kit Rate: 4.32 % (the input this scenario stresses; the baseline uses 6)
  • BOM Audit Cost: 900 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Kitting completeness cost = kits assembled x shortage recovery cost x incomplete-kit rate + BOM audit cost.
  • Total kitting completeness cost works out to 2,801 $ at these inputs, and this is the headline figure for the scenario.
  • Kitting completeness cost per unit works out to 3.5 $ / piece at these inputs.
  • Variable kitting completeness cost works out to 1,901 $ at these inputs.
  • Fixed kitting completeness adder works out to 900 $ at these inputs.

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 20.88% below the baseline at 2,801 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to incomplete-kit rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats every incomplete kit as costing the same flat recovery amount; a missing single-source filter that halts a build costs far more than a missing clamp, so blend your recovery rate accordingly.

Results at a glance

  • Total kitting completeness cost: 2,801 $ (headline result)
  • Kitting completeness cost per unit: 3.5 $ / piece
  • Variable kitting completeness cost: 1,901 $
  • Fixed kitting completeness adder: 900 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Kitting Completeness calculator, set incomplete-kit rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.