As you can see, the more process steps you have, the more challenging it will be to get an item through the system without any issues. Measuring and comparing the quality of assembly processes has been an elusive endeavor for some time. (April 2015). Many other measures of productivity and efficiency fail to account for the cost of rework and in many facilities rework can be a significant portion of the time and value added to final production. Most obviously it doesn't account for the down time, production schedule, or capacity of a given process. Here are our “top six” essential manufacturing KPIs to get you started. In a manufacturing setting, this tells you the overall proportion of acceptable results; if the number of units of acceptable quality at the end of the process is the same as what can be expected given what is fed into the process, then you have achieved a 100% Quality Yield.1, However, QY only considers the final yield and does does not take into account such activities as diversion for re-work or re-testing. A better target would be a range from 3 to 6 sigma, or 93.33% to 99.9966% — the higher the better, of course. Required fields are marked *, (C) 2020 Velaction Continuous Improvement, LLC. Unfortunately, In the case presented here, manual assembly is not world-class (best-in-class value should be a DPMO below 1,300, not above 5,000), which explains its 22 percent contribution to the total defect distribution. Allentown, PA USA First Pass Yield Percentage of units that meet specifications without any rework or repair. Process modeling and diagnostic tools to identify improvements and automate processes. Reliability principles are the basis for calculating the rolled throughput yield. Using the first pass yield equation above, the FYP is: That means that even with 4 processes performing at a 95% yield, one out of every 5 products will not make it through your system without needing rework. Whether one defect is referenced "bent lead," "open solder" or "missing solder," it is still only one defect, not three. For an analysis of the DPMO at each process step, it may be necessary to add the number of glue dots to the defect opportunity count as defined above. For aluminium components, first pass yield is increased from 95.75-95.99% after the implementation of action plan is mentioned in Fig. Customizable busines process workflow templates. most manufacturing teams only have the ability to produce an aggregated OLE for If you really want to improve quality, you must find a way to track this sort of activity. products fail their tests will allow you to examine the root cause of any your most important assets: your people. Your plantwill hav… You Box 939, Old Lyme, CT 06371-0939; (860) 434-8740; Fax: (860) 434-8742; E-mail:; Web site: measure the KPIs you want to track. If you would like information on this product please enter your email below. It’s You probably know the theoretical labour The goal should be to improve processes, not catch violators. First Pass Yield is an important manufacturing metric for measuring quality and production performance and there are many benefits to including first pass yield in the manufacturing executive's dashboard. Peter Drucker, and this certainly holds true for the manufacturing environment. Matthew Littlefield on Thu, Jan 24, 2013. RG12 8FB +44 (0) 1344 535 120, MESTEC Limited, The Lightbox, Willoughby Road, Bracknell. “If you can’t measure it, you can’t manage it,” so said Management Consultant The pristine yield is not a fully satisfactory metric for benchmarking purposes because it inherently varies with the board design complexity, but at least it is a truer representation of the process quality than FPY. FPY is also one of the components of Overall Equipment Effectiveness (OEE). But the total number of processes also has a huge impact. continuous improvement from your starting point. First Pass Yield (FPY) is an indicator that gauges the production and quality performance of a Manufacturing group, based on the number of good vs. defective units produced. biggest performance improvements. safety as a key metric. Overall line utilization... View White Paper. Click the image to see the full size version. based on the number of touch terminals you need, which makes it affordable and It does not provide a valid comparison between different products or competitors because it does not factor in the impact of board design complexity. Tracking On-Time-In-Full (OTIF) delivery achievement Very often continuous improvement initiatives are focused on the reduction of waste and inefficiency, which can be hidden from analysis if first pass yield is not measured. ). Tracking where and why your products fail their tests will allow you to examine the root cause of any issues. bill? easy to budget for. When passing through the second station all 5 units pass a 100% first pass yield. Download the eBook to learn about the difference between "validation" and "qualification". should formally track every complaint and track and monitor incident floor, you may face one of two problems; either you don’t know which key Consolidated existing first pass yield is charted below in Fig. Like OLE, the devil is in the detail. 3%, but as Production Manager, that level of detail won’t enable you to find The Six Sigma quality measure refers to a process in which six standard deviations fit between the target value and the customer’s specified limits. Your Finance To be able to First pass yield is a good measure of the effectiveness of a process and the elimination of waste from that process. It disregards online inspection and touch-up, which enhance FPY numbers and add to cost. For example, many factories will have identified That means that even with 4 processes performing at a 95% yield, one out of every 5 products will not make it through your system without needing rework. (per cent labour hours lost to rework or scrap). Performance(actual speed vs standard speed) 3. Although this research can be tedious, it is necessary for a true quality measure of each step. As you can infer from the equation, the effectiveness of a process plays a big role in determining first pass yield. Call: 844-650-2888 Email: It’s This product is currently not available through the website. Percentage defect distribution for world-class process quality. Proven leading practices that you can implement for your business. Availability(actual running time vs running time) 2. manually intensive industries, improving labour productivity will also help to OEE has been widely adopted, OLE is rarely tracked in detail. will ensure that you are satisfying your customers’ demands. For these reasons, and many others, first pass yield is often included as the first term of the Overall Equipment Effectiveness (OEE) formula. (April 17, 2015). Watch Velaction Videos | Visit Our Continuous Improvement Store. © 2001 - 2018 Fisher Clinical Services, Inc. Johannes joined Fisher Clinical in 2013 as Director, Quality and Regulatory Affairs. Director might be satisfied to know that your business’s overall scrap rate is Detailed OLE tracking Although this research can be tedious, it is necessary for a true quality measure of each step.

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