Surgical Robotics Manufacturing worked example

Inspection Bottleneck with severity if a defect escapes inspection of 15 score: a worked example in surgical robotics manufacturing

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

The inputs for this scenario

  • Severity if a defect escapes inspection: 15 score (raised for this scenario; the documented default is 6)
  • Occurrence rate of the inspection escape: 4 score (unchanged)
  • Detection difficulty at the inspection step: 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 severity if a defect escapes 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 severity if a defect escapes inspection is genuinely sustained, not just peaked for a shift. RPN treats all three factors as equally weighted multipliers, so a high-severity, low-occurrence risk can score the same as a moderate one — always review severity independently for safety-critical items.

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.