How to Calculate First Pass Yield

How many bottles are filled versus volume of soda lost?
How many bottles are filled versus volume of soda lost? (Image: juananbarros/iStock/Getty Images)

First pass yield is a measure to evaluate the initial efficiency of a multistep production process. As opposed to first time yield, first pass/throughput yield reviews the material efficiency of a process rather than the time efficiency.

Things You'll Need

  • Process log
  • Calculator

Review the production process for a product, organizing it into segregated and relatively independent steps. Also determine the base measure for evaluation that can be independently confirmed at each step of the process.

For example, in soda production, a consistent production measure for review would be amount of sugar at each stage of production per volume of fluid, the volume of fluid at the end of each process segment, or weight of actual materials at each stage.

Calculate the material efficiency of each section of the process, including products that are reprocessed as acceptable even if they were unaccepted during the initial process. For example, if the production line is for labeling cans, include any cans that failed initial runs due to dents that were able to be repaired. Do not include cans that were unusable and set aside as scrap.

The yield for each individual process is the number of end products divided by the units of measure inputted into the process. For example, the number of labeled cans sent to next production phase divided by number of cans sent into the labeling process.

Calculate the first pass yield (FPY) of the overall process by multiplying the yield percentage of each step against each step.

Example: FPY (Overal) = FPY (Process A) x FPY (Process B) x FPY(Process C).

Check calculations with actual production by measuring the number of units at the end of all processes versus the input of the process.

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