FPY requested for an industry that does not have rework

[nick.leivers]

Hello all:

We are are printing company (labels for both medical/pharma and automotive customers). One of our customers has asked that we provide First Pass Yield data.
In our manufacturing process:
1. Due to inherent "noise" in flexographic and screen printing, we create waste (if the customer orders 100 labels we will book the manufacture of 120 on the press)
2. We cannot rework any prints... it is first pass or nothing
3. between set-up (preprint) and run-out (post-print) we have waste material (our ratio is approximately 2:1 for material area allocated to the job versus material area of the finished printed product)

How can I define an equivalent KPI to FPY in this scenario?

Would i be in the wrong to state the following:
If we manufacture 10 jobs per month for 100 labels each: 9 of the jobs met the customers requests (100 labels shipped) and 1 did not (90 labels shipped): our FPY is 99% (990 labels delivered out 1000 ordered)?

 

[John C. Abnet]

Hello all:

We are are printing company (labels for both medical/pharma and automotive customers). One of our customers has asked that we provide First Pass Yield data.
In our manufacturing process:
1. Due to inherent "noise" in flexographic and screen printing, we create waste (if the customer orders 100 labels we will book the manufacture of 120 on the press)
2. We cannot rework any prints... it is first pass or nothing
3. between set-up (preprint) and run-out (post-print) we have waste material (our ratio is approximately 2:1 for material area allocated to the job versus material area of the finished printed product)

How can I define an equivalent KPI to FPY in this scenario?

Would i be in the wrong to state the following:
If we manufacture 10 jobs per month for 100 labels each: 9 of the jobs met the customers requests (100 labels shipped) and 1 did not (90 labels shipped): our FPY is 99% (990 labels delivered out 1000 ordered)?

Good day @nick.leivers ;
A- Does/will this data provide a benefit to your organization ?
a) If the answer is "YES", then develop this in a manner that suits YOUR organization

b) If the answers is "NO....
i. Why does your customer (the entity or a single individual ??) want this data?
ii. What will the customer use it for/ how will THEY benefit?
iii. What ENTITLES your customer to collecting / reporting this data?


Be selfish. "Things" done simply to satisfy a request and providing no benefit to the organization....
- frustrate leadership
- frustrate the members responsible
- are generally "fragmented" from the ebb and flow of developed systems and, therefore, are difficult to manage/sustain.



Hope this helps.
Be well.

 

[Miner]

You can still calculate First Pass Yield (FPY) even though you have no rework. The FPY calculation only considers the good product that has passed through an operation the first time. Both scrap and rework are subtracted from the total, so even though rework may be zero, you obviously have a lot of scrap in your process. Note: First Pass Yield is used for individual operations. For the entire process, you should use Rolled Throughput Yield (RTY). RTY is the product of all the FPYs in the process.

 

[Bev D]

FPY is your manufacturing yield not your shipping ‘yield’. Customers ask for it for the same reason they ask for Ppk values: either they want to understand the capability / waste of your processes OR they are just checking the supplier quality box.

for you FPY can be a simple calculation it het number of good labels yielded divided by the number of labels started. So if you start 120 labels and get 110 then your FPY is 91.6%

 

[nick.leivers]

I will have to discuss an alternative KPI with the customer as they are requiring a minimum of 98% for RTY which would be unattainable in our industry.

Thank you everyone for the advice.

Regards
Nick