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Internal or External PPM form or template wanted

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Marc

Fully vaccinated are you?
Staff member
Admin
#2
Are you looking for a formula for a spreadsheet or an entire generic spreadsheet?
 
D

dbzman

#3
I also need this. I have been asked to develop PPM KPI for my facility. I have never used the PPM method. I have always looked at %.

I was looking at using work orders and determining how many we have that are defective. It is hard to use parts since we batch process the parts. Work orders would be more appropriate.

Thanks!

:thanx:
 

E Wall

Just Me!
Super Moderator
#4
I was looking at using work orders and determining how many we have that are defective. It is hard to use parts since we batch process the parts. Work orders would be more appropriate.
It's simple math to calculate: Defective Qty / produced = % x 1,000,000

If you use batch numbers, you would then have to indicate the entire batch as an issue. For example say each batch represents 25,000 parts and you have produced 500,000 parts in whatever period you're covering. Then lets presume you have 5 defective parts total ocurring in all produced but they only ocurred from two of the batches.

If you calculate by parts PPM = 10; however if calculate by batch PPM = 100,000

if you break out by batch:
2 of 25,000 is PPM = 80 (and 3 defects would be 120) but this is an incomplete picture of total production unless you point to two batches out of 20 which would look really bad (numerically). We have a customer that expects the PPM for their products to be less than 50 which equates to failure rate of 0.005%.
 
Last edited:
D

dbzman

#5
It's simple math to calculate: Defective Qty / produced = % x 1,000,000

If you use batch numbers, you would then have to indicate the entire batch as an issue. For example say each batch represents 25,000 parts and you have produced 500,000 parts in whatever period you're covering. Then lets presume you have 5 defective parts total ocurring in all produced but they only ocurred from two of the batches.

If you calculate by parts PPM = 10; however if calculate by batch PPM = 100,000
if you break out by batch:
2 of 25,000 is PPM = 80 (and 3 defects would be 120) but this is an incomplete picture of total production unless you point to two batches out of 20 which would look really bad (numerically). We have a customer that expects the PPM for their products to be less than 50 which equates to failure rate of 0.005%.


We will have anywhere from 500 to a 1,000 invoices per month. Say that the average batch per invoice is 2, since the number of batches per invoice can vary. That gives us a maximum of 2,000 batches. I cannot say how many parts are in each batch because it varies from 1 to a few hundred; depending on the part size and weight per customer.
Each batch of parts are put into a furnace and processed. If we have a batch that has even one defective tested the total batch is rejected. Using parts as a measure would also be misleading since we could have two parts in one batch for a customer versus 200 parts in another batch for a different customer. Rework/defective is determined by the batch.
Batch/Total Batches = % X 1,000,000
If we process 2,000 batches per month and have 7 batches rejected we would have 3,500 PPM rejected. A large number compared to what I have seen in other posts.


A little confusing for me.

:bonk:
 

E Wall

Just Me!
Super Moderator
#6
A large number compared to what I have seen in other posts.
Because most do not use batch info for PPM, rather they use part production totals for the calculation.

From your statement you are rejecting the batch for further inspection/rework/scrap. IMHO the data from the batch inspection should be used against the actual part numbers in for your determination using rework/scrap numbers combined to identify those that didn't pass first-time-thru.
 
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