Sterilization & Sterile Barrier Manufacturing worked example

Inspection Bottleneck with escape severity if a defect passes inspection of 3 score: a worked example in sterilization & sterile barrier manufacturing

Here is what the math looks like when conditions slip. We hold every other input steady and drop escape severity if a defect passes inspection to 3 score, then walk the calculation through step by step. Estimate inspection bottleneck for sterilization and sterile barrier manufacturing using production-ready inputs so teams can rank risks and decide which issue needs containment, controls, or escalation first.

The inputs for this scenario

  • Escape severity if a defect passes inspection: 3 score (the input this scenario stresses; the baseline uses 6)
  • Likelihood of the defect occurring: 4 score (held at the documented default)
  • Inspection detectability of the defect: 3 score (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Inspection bottleneck risk score = inspection bottleneck severity score × inspection bottleneck occurrence score × inspection bottleneck detection score.
  • Inspection bottleneck risk score works out to 3.35 score at these inputs, and this is the headline figure for the scenario.
  • Inspection bottleneck severity score works out to 3 score at these inputs.
  • Inspection bottleneck occurrence score works out to 4 score at these inputs.
  • Inspection bottleneck detection score works out to 3 score at these inputs.

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 26.37% below the baseline at 3.35 score.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to escape severity if a defect passes inspection, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 3.35 score (headline result)
  • Inspection bottleneck severity score: 3 score
  • Inspection bottleneck occurrence score: 4 score
  • Inspection bottleneck detection score: 3 score

Run it with your numbers

  • To rerun this with your own numbers, open the live Inspection Bottleneck calculator, set escape severity if a defect passes inspection to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.