First pass yield analysis and improvement at a low volume. The six sigma definemeasureanalyseimprovecontrol approach resulted in a reduction of tolerancerelated problems and improved the first pass yield from 85% to 99. We test various units that require adjustments in regards to rig, free pins, tensions, etc. Also referred to as the quality rate, the percentage of units that completes a process and meets quality guidelines without being scrapped, rerun, retested, returned or diverted into an offline repair area. A value based on moving a set of like products through multiple operations with no rework or fixing of defects that occur along the manufacturing process.
First pass yield fpy multiply the individual quality measures for each process. Quality improvement through first pass yield using. However, this number holds valuable information about several surrounding processes. Start a free trial to create custom apps, or tailor a template. Would having to make one of the aforementioned adjustments constitute a failure.
Value creation key data required to quantify the value delivered by cvp390 first pass yield finest feature component the major defects the defects that cause a board to be scrapped total volume of boards manufactured per month value of finished board. First pass yield improvement fpy, pareto analysis, qc tools, whywhy analysis. The first pass yield or throughput yield of the stamping process is 0. Yield ae rme pmi total pmi reaction pmi workup conversion selectivity benzylamine 1,3 propandiol metbucarbonate kotbu water ethyl acetate na2so4 pmi reactants, reagents, catlyst. Edwards deming quality is the heart and soul of any manufacturing unit. This represents the likelihood that a deliverable will go through all process steps without a qualityrelated problem. In contrast, first pass yield fpy, also known as first time yield or throughput yield, is calculated from the yields of each individual process. Skus sometimes built to order that often involve complex manual workflows. The reliability formula for a system in series with n.
First pass yield fpy is a metric that indicates the percentage of items moving through a series of processes without any problems. First pass yield going forward we appear to have solved the big reasons for fallout 80% however. Pdf process improvement using six sigma to improve. For aluminium components, first pass yield is increased from 95. Should that rework be included in the first pass yield assuming all products pass the function test lets say a quantity of 10 would you consider fpy as 100%. Trying to calculate first pass yield but have a question. Pdf first pass yield improvement in fuel injection pump delivery.
The results of this test were a 75 percent first pass yield. Increased production new, faster evaluation methods keep. Enter any data that you and the team have defined important to the process. The immediate goal of six sigma is defect reduction. Free run, external 12, rf burst, video, internal sequence analyzer. The case study presented below is the actual storyboard used by the six sigma improvement team to document the project and the results. With a goal of achieving a 100 percent first pass yield, benchmark continues to work on improving the function of this test with the new solder paste. A first pass yield is a quantitative numerical value, usually presented as a percentage, that indicates the amount of product being produced related to how much is used in production. If no defects are corrected throughout the process the rfpy is usually very low. Free lean six sigma training debates whether fpy or rty is the best measure of yield. One could argue that its just a number representing ratio products made right first time against total output batch, shift, order etc. Rolled throughput yield rty also known as the first pass yield the probability or percentage of time that a manufacturing or service process will complete all required steps without any failures. Fpy first pass yield a measure of quality in a process that reflects the percentage of product made correctly without any rework or corrective activity. A free powerpoint ppt presentation displayed as a flash slide show on id.
First pass yield fpy, also known as throughput yield tpy, is defined as the number of units. For brass components, first pass yield is increased from 96. Chapter 5 illustrates the development of a standardized production manual for. Ppt first pass yield powerpoint presentation free to. Consider now an operation that has three processes.
The purpose of this paper is to illustrate the power of the six sigma methodology in improving the first pass yield of a highprecision. Reliability principles are the basis for calculating the rolled throughput yield. Improving first pass yield and reducing defect cost of honing machine 255 research methodology the paper follows six sigma based dmaic methodology to analyze and find the factors affecting the fpy of the honing process as well as to find the cause of defects in delivery valve body. When developing the vsm, you might see that a bottleneck exists because of. Pdf first pass yield analysis and improvement at a low volume. Typically wire, wire end, or pin is used fpy uses 1 opportunity per assembly. First pass yield units produced with no rework total units of products entering the process fpy is an important manufacturing metric that measures quality and production performance. As an example, if each process operates at a no rework rate of 90%, and this 90% goes through 5 processes, your rfpy is. First pass yield fpy is one of manufacturing kpis that in my mind should always be treated with caution.
It has a process focus and aims to highlight process improvement. You can also get the total process yield for the entire process by simply dividing the number of good units produced by the number going in to the start of the process. In specific, primary data collection and analysis of factors. If each wire represents an opportunity and you produce 500.
But yield on its own can be deceiving if parts can be reworked or retested. In lean training courses, the concept of yield is discussed as a measure of the quality of a process. The first pass yield fpy at dynamic electrical test det was low but stable at an average of 61%. Use the template to highlight to designers the costdrivers and yield issues caused by spec requirements, process capabilities, assembly requirements, etc propose your ideas on how to reduce cost, touch time andor improve yield. Increase first pass yield with superior signal purity and measurement accuracy get up and running in. You can quickly and easily break down true first pass yield from a global level, into more granular statistics for different products, revisions, test stations, periods, processes, rolled throughput, and actual failing test steps. Basic six sigma metrics lean six sigma free training. Quality improvement through first pass yield using statistical. Improve quality, you automatically improve productivity w. Pdf this work was carried out in an automotive sector, for single cylinder fuel injection pump pf33 delivery valve. Only good units with no rework or scrap are counted as coming out of an individual process. An application of six sigma methodology for improving the.
This is your production rate of assemblies per month converted to opportunities per month. Then, complete a new calculation by including customer valueformoney vfm, which is sales price divided by manufacturing cost. The number of flaws per million possibilities was 11 276 table 1, which is an extremely high. High first pass yield at ict ecoreltm free 3056 4056. Improve first pass yield in low volume discrete manufacturing lines with tulip. In the case of the example tireinflation process, the hidden factory of inprocess inspection and rework accounts for 0. The teams goal was to improve fpy from 61% to 90% a 29% improvement by january 2003.
An application of six sigma methodology for improving the first pass yield of a grinding process article pdf available in journal of manufacturing technology management 251 january 2014. Nowadays, the competitive manufacturing background. Indicates what percentage of the products will pass the production process with no rework or scrap, therefore in proper quality. An analysis was done to understand the working and importance of the quality metrics, first pass yield and quality noti cations per module, to understand the reasons for its stagnation over the past couple of years at the assembly plant. Also related, first time yield fty is simply the number of good units produced divided by. First pass yield fpy, also known as throughput yield tpy, is defined as the number of units coming out of a process divided by the number of units going into that process over a specified period of time. First pass yield or quality yield, wait whats the difference. First pass yield example velaction continuous improvement. First time yield fty is a calculation used to determine when the total number of acceptable product leaves the process when reworkscrap are counted, but only if the rework performed corrects the defects. Lead free noclean solder paste features sac snagcu alloys are currently the industry choice because they have excellent soldering and. Rework equipment was tested for use on ball grid arrays. If using a yield metric other than first pass yield fpy, at what level do you assess risk of a defect.
Fpy is calculated by dividing the units entering the process minus the defective units by the total number of units. First pass yield is determined by multiplying the yield of all the processes in a system. The objective of this study was to improve first pass yield fpy and reduce the defect rate of a product. Improving first pass yield and reducing defect cost of.
This article compares rolled throughput yield vs first pass yield. This term is typically used in reference to manufacturing processes, and it can be used for individual steps in a process or for an overall process. First pass yield analysis and improvement at a low. Step 8 add smiley faces it is important to understand the amount of capacity in labor at each process. First pass yield process 1 yield process 2 yield process n yield click the image to see it in full size.
Fpy first pass yield is an indicator of production quality. Use the same metrics for performance quality pq referenced in the articlepq multiplied by first pass yield. Help measure the effectiveness of a process help eliminate waste from the process account for the cost of rework. The first process has a first time production yield of 98. Our customers benefit from the effective guidance of a topdown approach, where true yield metrics are at the center.
An application of six sigma methodology for improving the first pass. Fty or first pass yield is a tool for mearsuring the amount of rework in a given process. 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. Ecoreltm free 30564056 typical reflow profile 0 50 100 150 200 250 300 0 50 100 150 200 250 300 350 seconds 217. Quality improvement through first pass yield using statistical process control approach author.
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