Enter each step’s first pass yield and cost per defect to get rolled throughput yield, parts reworked and scrapped per year and the cost of the hidden factory.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Bars: FPY of each step. Line: chance of a part reaching that point with no defect.
Annual defect cost by step, largest first, with cumulative percentage.
Cash flow of the improvement: investment in year 0 and annual savings escalated at the rate entered, discounted at the MARR.
The report gathers this page's inputs, results, equations, assumptions and references, with fields for project, engineer and revision. In the print dialog, choose Save as PDF.
Multiply the first pass yields of all steps. Five steps at 95% each give an RTY of 0.95⁵ = 77.4%: nearly one part in four goes through some rework or scrap.
Final yield counts good parts at the end, including reworked ones. FPY counts only those that passed the first time. The gap between them is the hidden factory.
At the step with the highest cost on the Pareto, not necessarily the lowest FPY: a late defect costs more because the part has absorbed more work and material.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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