Wearable Medical Sensors worked example

Inspection Bottleneck with inspection escape severity of 3 score: a worked example in wearable medical sensors

This worked example runs the inspection bottleneck numbers for a tougher week than the baseline: inspection escape severity of 3 score instead of the typical 6 score. Estimate inspection bottleneck for wearable medical sensors using production-ready inputs so teams can rank risks and decide which issue needs containment, controls, or escalation first.

The inputs for this scenario

  • Inspection escape severity: 3 score (the input this scenario stresses; the baseline uses 6)
  • Defect occurrence likelihood: 4 score (held at the documented default)
  • Inspection detection difficulty: 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 inspection escape severity 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.
  • Use it during process FMEAs, inspection redesign, or when deciding which inspection station to add capacity or automated vision to first. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

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 inspection escape severity to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.