What Is First Pass Yield and How to Improve It?

To gauge the effectiveness of a manufacturing process, manufacturers often rely on a KPI called First Pass Yield. In this article, we’ll define First Pass Yield and understand how SMEs use it to improve their overall manufacturing operations efficiency to produce a high-quality product.

What is First Pass Yield?

First Pass Yield, or FPY is a manufacturing Key Performance Indicator (KPI) that measures the percentage of manufactured units that meet quality standards or finished product criteria set by the manufacturer. The percentage is based on a single run, often defined by a designated time frame such as a shift. It could also be determined by a test run to give the production team time to make final adjustments to increase process efficiency before processing a full run.

A satisfactory product is evaluated based on its defined quality parameters. Deviations may require the product to be reworked to meet the standards or scrapped because it is too far out of specifications to warrant repair or rework.

First Pass Yield vs. Rolled Throughput Yield

The First Pass Yield metric is sometimes used interchangeably with the term Throughput Yield (RTY or Rolled Throughput Yield). However, a distinction must be made between these two KPIs.

Whereas FPY is calculated using one simple manufacturing time frame and one single process, RTY is calculated by considering the accumulated first pass yield scores during multiple time frames or, more often, when there are multiple stages in the manufacturing process. We look at examples of each below.

How to calculate First Pass Yield?

The basic First Pass Yield formula is simple:

FPY = [Number of good units] ÷ [Total number of units entering the process] x 100. 

For example, if there were a total of 200 units in process and 180 of them were acceptable, the FPY would be 180 ÷ 200 x 100 = 0.90 or 90%. An FPY score of 100 is almost impossible to achieve. However, the higher the score, the more efficient the operation.

In some situations, minor defects that don’t affect the quality of the product could be considered “acceptable units” and would be used as “good” in the calculation.

Practical calculation examples

A simple FPY example would be the production of a simple item such as a plastic drink tumbler. The number of tumblers succeeding a quality check is divided by the total number of tumblers manufactured in a production process, divided by 100.

A multi-stage scenario could involve the same plastic tumbler but with an additional stage or process that screenprints a logo on it. Here, the FPY is calculated individually for each stage. Then those FPY totals are multiplied together to get the Rolled Throughput Yield (RTY).

Let’s say the FPY for the tumbler forming was 85% and the logo printing was 95%. The RTY would, therefore, be 0.85 x 0.95 = 0.8075 or roughly 80%.

The importance of FPY

The First Pass Yield metric is a vital KPI because it gives the manufacturer insight into the overall efficiency of their manufacturing processes. Think of it as a barometer that indicates whether the operation is running smoothly and efficiently, or whether some tweaks should be made to increase product quality and further improve output. 

The direct financial impacts of maintaining a high FPY include reduced raw material waste for products that must be scrapped and elimination of labor costs associated with rework.

Operational benefits include process stability and predictability. Knowing what needs to be done to maintain a high FPY can help a manufacturer better understand how to improve capacity utilization and the reliability of production scheduling.

FPY can also be used as a diagnostic tool. Using historical FPY data, a manufacturer can determine various potential problems, including the need to repair or upgrade process equipment. When they get a low FPY score, they can check to see what quality issues they’re having and often track them back to an individual machine or stage in the process. If scheduled properly, repairs can often be made without substantial production downtime.

Finally, FPY scores can serve as benchmarks for improvement initiatives, including upgrading or replacing defective machinery. Tracking the First Pass Yield allows one to measure the effectiveness of process changes. 

For example, increasing line speed often leads logically to increased throughput. However, it may lower First Pass Yield scores instead. In our tumbler example above, an increased line speed could cause out-of-register colors in the logo or air bubbles in the ink, resulting in splotches. This causes defective products. FPY numbers allow the manufacturer to tweak the speed to optimal levels to decrease or eliminate printing errors.

8 ways to improve First Pass Yield

1. Implement structured improvement practices such as Lean Manufacturing principles and tools or take a Six Sigma DMAIC (design, measure, analyze, improve, and control) approach.
2. Optimize production processes. Use standardized operating procedures (SOPs) and simplify complex processes whenever possible, eliminating bottlenecks or activities that don’t add product value.
3. Implement strict inspection protocols at critical stages to boost quality assurance measures. Deploying technologies for early defect detection and applying Statistical Process Control (SPC) can eliminate a lot of human error.
4. Implement mistake-proofing mechanisms (poka-yoke) that make it impossible—or at least very difficult—for errors to occur in the first place. This might include physical design features that prevent incorrect assembly, sensors that detect misalignment, or automation logic that halts operations when anomalies are detected.
5. Invest in comprehensive employee training. Provide thorough technical training to all production line workers. Foster quality awareness and ownership in the manufacturing team. Help employees develop systematic problem-solving skills.
6. Strengthen supplier relationships. Only partner with reliable, quality-focused suppliers who implement incoming quality checks as rigidly as you do. Establish clear quality specifications to eliminate surprises. Develop collaborative improvement initiatives with companies in your supply chain whenever possible.
7. Implement proactive maintenance strategies. Don’t wait until a machine breaks before it’s serviced. Establish preventive maintenance programs that use predictive maintenance procedures such as thermography. Monitor equipment performance in real time to detect anomalies. Track maintenance metrics and their impact on FPY to ensure that what’s being done works toward Overall Equipment Effectiveness (OEE).
8. Foster a culture of continuous improvement. Encourage data-driven decision-making over guesswork. Empower employees to identify and resolve issues on their own. Form cross-functional improvement teams and set and monitor quality goals for them to adhere to.

How manufacturing ERP software can increase production efficiency

Particularly in high-speed manufacturing operations, human error can leave many inefficiencies undetected. Manufacturing ERP software provides critical production planning and inventory control, ensuring materials and components are available when needed. Modern MRP solutions typically include production scheduling and shop floor control capabilities, inventory management functionalities, and demand forecasting tools to optimize resource allocation.

Robust Manufacturing ERPs include or integrate with Manufacturing Execution Systems (MES), creating a comprehensive solution that permits real-time production monitoring while maintaining proper material flow. This integration supports quality check tracking and documentation throughout the manufacturing process, significantly reducing quality defects.

The ability of these systems to coordinate material availability and inventory quality checking with production activities facilitates greater communication and collaboration across departments while providing real-time insights into key metrics. The advanced analytics tools within these systems streamline continuous improvement efforts by helping track both material and finished good quality issues.

Leverage data-driven FPY for manufacturing excellence

As we have seen, First Pass Yield is a crucial metric when striving for manufacturing efficiency. Rework and product scrapping both waste valuable resources and lower a company’s profit margins. By tracking and examining FPY, a business finds ways to improve its manufacturing process to decrease, if not eliminate, errors by finding the root causes of defects and correcting them.

Even minor adjustments to the process will increase the product quality and lead to continuous improvement. And every step toward successful operations is a step toward customer satisfaction as well.

When combined with smart tools like MES and MRP systems, and supported by a culture of continuous improvement, FPY becomes a strategic asset. Manufacturers who track and act on their FPY data are better positioned to reduce costs, meet delivery deadlines, and produce consistently high-quality products.

Key takeaways

• First Pass Yield is a manufacturing KPI that measures production efficiency by tracking the percentage of products manufactured correctly on the first attempt.
• A high FPY directly correlates with reduced waste, lower costs, and improved customer satisfaction. 
• Common causes of low FPY include material quality issues, equipment problems, human errors, and inefficient processes.
• First Pass Yield can often be improved by implementing more structured manufacturing practices, process optimization techniques, tracking quality control KPIs, investing in employee training, and integrating manufacturing execution systems (MES). 
• Manufacturing software provides real-time visibility and analysis to identify improvement opportunities, eliminating guesswork through data collection automation.

Frequently asked questions (FAQ)

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