Pharma Stage Yield and Reconciliation Worksheet
A batch record reviewer checks yield and reconciliation at every stage. This worksheet does the arithmetic for you and flags where unaccounted material accumulates, ready to export to Excel or PDF.
| Stage | Input (kg) | Good output (kg) | QC samples (kg) | Rejects and waste (kg) | Unaccounted (kg) | Stage yield | Reconciliation | |
|---|---|---|---|---|---|---|---|---|
0 | 100% | 100% | ||||||
0.7 | 97% | 99.4% | ||||||
0.2 | 99% | 99.8% | ||||||
0.5 | 96.4% | 99.6% | ||||||
0.3 | 98.1% | 99.7% |
Enter weights from the executed batch record. Compare each stage with the yield limits in your master batch record. Stage inputs can include in-process returns when your procedure allows it. Large unaccounted values need an explanation in the batch record or a deviation.
Yield trending from ERP data
Optional expert review of pulling stage yields from your ERP production orders.
Optional. The tool and every export work without this. No spam.
How to use it
Add one row per stage with the material that went in, the good output, QC samples and rejects or waste. The sheet computes unaccounted material, stage yield and reconciliation percentage. Replace the example rows with your own. Keep the same units across stages and make sure the output of a stage matches the input of the next one, otherwise the cumulative picture will be off.
Formulas
Stage yield equals good output divided by input. Reconciliation equals output plus samples plus rejects divided by input, and should be close to 100 percent. Unaccounted is input minus all accounted streams. In the example, granulation has 0.9 kg unaccounted, roughly 0.75 percent of its input, which many sites would explain by dust and equipment hold-up rather than a deviation.
How to read results
Compare yield and reconciliation with the limits in the master batch record rather than a generic percentage. A stage with perfect reconciliation but low yield suggests a process problem, while good yield with poor reconciliation suggests weighing or recording errors. Trend the same stages across batches in a spreadsheet or your ERP to catch drift early.
Frequently Asked Questions
What yield is acceptable?
It depends on the product and stage and is set in the master batch record, usually as a range. There is no universal percentage, so use your approved limits.
What reconciliation limits are normal?
Limits are set per process, often a narrow band around 100 percent. Anything outside needs documented investigation under your quality system.
Should samples be included?
Yes. Retained, QC and in-process samples are legitimate removals and must be accounted for, otherwise the unaccounted value looks worse than it is.
Can I use grams or units?
Yes, as long as every column in a row uses the same unit. The percentages do not depend on the unit chosen.
Netray can read batch actuals and production orders from your ERP and bring stage yields into one trend view on your own servers. Ask for an expert review.
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