Need Help with FPY Data in Assembly Process

#1
Hey, everybody. I am the QE for a company and need help regarding an AutoTester. So we have a product we assemble in a U shaped cell. Once it is all assembled, they run it through HiPot in an AutoTester. If it passes, they then put a decal with the serial number on the unit. If it doesn't pass, then they either run it again until it passes, or try to determine why it failed, then rerun it. Once it passes, they then stick the serial number decal on it. The AutoTester day only shows a count of units passed and units failed. So if they have one unit that failed three times, then passed, it would show as 3 units failing and 1 unit passing. Management seems to be okay with this data, but I am not. I am trying to determine how to get an accurate count of fails and passes per unit so that its 1:1 not 4:1 as referenced above. Can anyone please help me so that I can fix this FPY issue? Thanks in advance!
 
Elsmar Forum Sponsor
#4
It is FPY that I am looking to improve. Management wants to see better FPY numbers, but to me, FPY isn't being recorded properly to get an accurate count of good vs bad. Showing that we have 3 bad and 1 good when they failed one part three times and it passed the fourth isn't reporting correctly in my opinion. I would love some feedback on thoughts as to how to improve upon this. If anyone has any knowledge of HiPot testing with an AutoTester, that would be very beneficial too since this is where they are pulling all of the data.
 

blackholequasar

The Cheerful Diabetic
#5
We use a Cirrus tester for our HiPot. There is some good data that you can collect from it via an Excel export. We have an internal calculation that we run to show a more accurate FPY. For us, the issue was opposite - we would have a cable with 40 connections and 10 of those would have faults so it showed one cable failed 10 times! Using DPMO helped us quantify it better. Does your HiPot have any sort of reporting applications that you can use? If so, I may be able to share the calculation excel that we use.
 
#6
I will have to check. I am new here and I get the FPY report from a daily report sent out. I need to dive deeper into that rabbit hole on Monday. Once I do, I will post back on here. I would appreciate any excel calculations. Thanks!
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#7
Welcome jsh298! It’s always nice to have accurate metrics as it typically can stop the wasteful arguments and questions regarding the accuracy of the report. But I think it’s important to remember that it’s not necessary. You can and should focus your efforts on solving the failures. The entire point of the metric is to help the organization identify and prioritize when there are an overwhelming number of failure types. But when it’s internal failures. You have immediate access to the failed units and the failure type and you can begin root cause analysis. Remember that FPY i sa one dimensional metric - multiple repeat failures are just as wasteful maybe even more so. Go fix the causes and your metric will take care of itself.
 
#8
I haven't been able to go look at the autotester this morning, but I have a side question regarding FPY. Thanks Bev D for the info! I am focusing on the failures and diving into those, but management is solely focused on FPY numbers (what boss says goes....) So, I realized this morning that they are using =(#passed autotester / #total tests) to get FPY. With the autotester just reporting # good and # bad so you cant differentiate how many times one pump got ran through the autotester before it passed, I think it should be =(1-(#failed / #good) to get FPY. I used my formula at my last job and it was always correct. Which one is right?
 
Thread starter Similar threads Forum Replies Date
R Lead auditor scenario (Need help) is this non conforming to ISO13485 Manufacturing and Related Processes 2
U Need Help With API Q2 Quality Manual Oil and Gas Industry Standards and Regulations 8
D Need some Help on 8D fault tree analysis Problem Solving, Root Cause Fault and Failure Analysis 6
K Screen printing ink and machine selection_ Need help Manufacturing and Related Processes 6
S Need help on "Country of Origin" Medical Device and FDA Regulations and Standards News 0
M Need Help With Information Security Asset Risk Register IEC 27001 - Information Security Management Systems (ISMS) 2
C ISO/ IEC 17021 Resource requirement (need help) Document Control Systems, Procedures, Forms and Templates 5
SocalSurfer AS9100 new certificate, but need QMS software, help Quality Assurance and Compliance Software Tools and Solutions 2
S Need help with analysing a survey on minitab Using Minitab Software 1
K A proposal for the model Quality Management - I need help for the project ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 3
R Probability - Need a help to solve the below question Statistical Analysis Tools, Techniques and SPC 5
8 Need Help - Runout - Function Gage Inspection, Prints (Drawings), Testing, Sampling and Related Topics 7
S New to FAIR, need help in filling it out AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 8
R Pls help --- Need expert advice on Video Measurement Measurement Uncertainty (MU) 0
Ajit Basrur Need help to understand HIPAA requirements ISO 13485:2016 - Medical Device Quality Management Systems 17
Z I need help with getting a CFS in China Manufacturing and Related Processes 2
S Need help wrapping my head around confidence vs beta error Statistical Analysis Tools, Techniques and SPC 2
P Received a minor for not having good measureables/goals. Need help with KPIs. IATF 16949 - Automotive Quality Systems Standard 52
A Failed the AS9120B Exam Twice.....Need Help AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 11
Ajit Basrur Need help in Conditional Formatting for the entire row Excel .xls Spreadsheet Templates and Tools 3
H Need help on Quality Improvement Plan (QIP) Quality Tools, Improvement and Analysis 5
S Help: Need Control Self Assessment Questionnaire for HR Departmental Functions Process Audits and Layered Process Audits 0
M Need help in Calibration of Directional Coupler General Measurement Device and Calibration Topics 2
L Need HELP with Internal Audit Program ISO 13485.2003 Quality Management System (QMS) Manuals 3
J Supporting Processes - Internal Audits - Need help settling a debate IATF 16949 - Automotive Quality Systems Standard 4
A Cpk Formula seems off, need help!? Capability, Accuracy and Stability - Processes, Machines, etc. 11
A Need Help With AEA Auditor Related Situational Questions AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 1
E Transformer Overload Test - Need help IEC 60601 - Medical Electrical Equipment Safety Standards Series 3
C I Need Help with Drafting Conventions!!! Design and Development of Products and Processes 4
M Need help on QMS Development in an AS9100C certified organization AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
R Need Help on Analysis: How to know potential causality model from historical data Problem Solving, Root Cause Fault and Failure Analysis 5
B Need help tracking training for my business Quality Assurance and Compliance Software Tools and Solutions 3
B Need help with a Control Plan for Encapsulation Mold / Trimming / Forming Tooling FMEA and Control Plans 9
S I need help from all of you bros Oil and Gas Industry Standards and Regulations 1
LRE67 Need help identifying this "thing" Coffee Break and Water Cooler Discussions 9
G Need help on Device Description in the Acceptance Checklist for Traditional 510(k) Other US Medical Device Regulations 2
K Need help finding a book on Documentation Book, Video, Blog and Web Site Reviews and Recommendations 8
J Need help/advice on video editing software etc..... Coffee Break and Water Cooler Discussions 8
L Need Help with Case Study Questions Manufacturing and Related Processes 16
W Help explaining the need for the Process Approach AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
Ron Rompen Unusual problem with Excel - Need some help Excel .xls Spreadsheet Templates and Tools 7
S Need help on new TS 16949 Rules IATF 16949 - Automotive Quality Systems Standard 5
M Need help with Network Analyzers and which DUT can be Calibrated with it Calibration and Metrology Software and Hardware 2
R Need help on defining scope for Design Verification File for Class III IVD 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 8
J Help I need your opinion on a News Letter Misc. Quality Assurance and Business Systems Related Topics 15
N Need Help Preparing for Medical Device Quality Engineer Interview Career and Occupation Discussions 2
B Need help on an application we are working on Coffee Break and Water Cooler Discussions 4
S Need help with Project Charter for my Six Sigma Green Belt Project Six Sigma 1
Q Need help on MSA study on a torque analyzer Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
B Need help in adding second location to FDA Registration Other US Medical Device Regulations 4

Similar threads

Top Bottom