Sterilization & Sterile Barrier Manufacturing worked example

Inspection Bottleneck with escape severity if a defect passes inspection of 15 score: a worked example in sterilization & sterile barrier manufacturing

What does the result look like when escape severity if a defect passes inspection reaches 15 score? The full calculation is worked below with real intermediate numbers. Use it when inspection bottleneck in sterilization and sterile barrier manufacturing needs a defensible ranking against other sterilization and sterile barrier manufacturing risks for the next review.

The inputs for this scenario

  • Escape severity if a defect passes inspection: 15 score (raised for this scenario; the documented default is 6)
  • Likelihood of the defect occurring: 4 score (unchanged)
  • Inspection detectability of the defect: 3 score (unchanged)

Working through the calculation

  • Applying the documented formula (Inspection bottleneck risk score = inspection bottleneck severity score × inspection bottleneck occurrence score × inspection bottleneck detection score) to the inputs above produces each figure below.
  • At this operating point the engine returns 8.15 score for inspection bottleneck risk score, the number this scenario is built around.
  • At this operating point the engine returns 15 score for inspection bottleneck severity score.
  • At this operating point the engine returns 4 score for inspection bottleneck occurrence score.
  • At this operating point the engine returns 3 score for inspection bottleneck detection score.

How this compares with the baseline

  • Against the tool's baseline example, where escape severity if a defect passes inspection sits at 6 score and the headline result is 4.55 score, this scenario comes in 79.12% above the baseline at 8.15 score.
  • A figure at this level is achievable when escape severity if a defect passes inspection is genuinely sustained, not just peaked for a shift. Scores are subjective ordinal ratings, so a risk number is only meaningful when the same scale and rating guide are used across all inspection steps compared.

Results at a glance

  • Inspection bottleneck risk score: 8.15 score (headline result)
  • Inspection bottleneck severity score: 15 score
  • Inspection bottleneck occurrence score: 4 score
  • Inspection bottleneck detection score: 3 score

Run it with your numbers

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

Last reviewed 2026-05-12.