Throughput Yield (TPY)

Also called First Pass Yield

Throughput Yield (TPY) is the number of acceptable pieces at the end of the end of a
process divided by the number of starting pieces excluding scrap and rework (meaning
they are a part of the calculation).
Rework IS a part of the TPY calculation. Use the process map as a guide for evaluating
each individual process.
TPY is used to only to measure a single process.
Sometimes only raw material is available at the start so it may be necessary to convert
the raw material to expected pieces that it should make, or use a unit of weight at the
start and weight out at the end to calculate final yield.
The unit of measure must be the same for the numerator and denominator throughout
the calculation.

Calculation (assuming all rework only takes one time to correct):

Process 1 TPY:
40 of the 50 pieces that entered Process 1 went through Process 1 correctly the first
time. Therefore Process 1 TPY = 40 / 50 = 80.0%
Process 2 TPY:

34 of the 46 pieces that entered into Process 2 went through Process 2 correctly the
first time through. Therefore Process 2 TPY = 34 / 46 = 73.9%
Process 3 TPY:
37 of the 46 pieces that entered Process 3 went through Process 3 correctly the first
time. Therefore Process 3 TPY = 37/46 = 80.4%

Process 2 has the lowest throughput yield but not necessarily the most costs. If a
scrapped piece in Process 3 has significantly more cost then Process 3 it may still be in
the teams best interest to improve. The later the process is downstream the more cost
are accumulated in the piece or part.
There is more direct material, direct labor, and/or manufacturing overhead in each
process as the part proceeds through its value stream. Process 3 at its initiation has all
the costs in Process 2 + the costs of Process 1.
There is another method to calculate TPY for a single process. If the DPU or defects
and units are known then:

Rework involves many of the 7-wastes and contains the hidden factory opportunity, it
is relevant to understand when guiding the team's direction.
Throughput Yield, TPY, and other yield metrics can serve as baseline scores (Measure
Phase) and final scores for Six Sigma projects (Control Phase).
The baseline score does not have to be a z-score and often this yield metrics are easier
for team and other company employees to relate with and understand.

Final Yield (FY)

Final Yield represents the acceptable pieces at the end of the process divided by the
pieces started. The FY excludes scrap.
In other words, if there are the same amount of pieces at the end as there were at the
start (without any being introduced in the middle) then there is perfect 100% final
yield.

Rework is not a part of the FY calculation. Use the process map as a guide for
evaluating each individual process.
FY does not depend on the number of processes involved. It is a high level
determination the percentage of good pieces that came out of the entire process
compared to the quantity started or that should have been made.
NOTE: Sometimes only raw material is available at the start so it may be necessary to
convert the raw material into expected pieces that it should make, or use a unit of
weight at the start and weight out at the end for the calculation.
Calculation from above example:
The unit of measure must be the same for the numerator and denominator throughout
the calculation.
Process 1 Yield: 46 passed / 50 entered = 92.0%
Process 2 Yield (itself): 46 passed / 46 passed = 100%
Yield AFTER Process 2: 46 passed / 50 entered: 92.0%
Process 3 Yield (itself): 37 passed / 46 entered = 80.4%
Yield AFTER Process 3 (also the same as the final yield of entire process):
37 passed / 50 entered
Final Yield = 74%
Process 3 has the lowest yield and probably the most cost associated since all the
material, labor, and overhead costs are already in the pieces from the previous
processes.
Final Yield and other yield metrics can serve as baseline scores (Measure Phase) and
final scores for Six Sigma projects (Control Phase). The baseline score does not have

to be a z-score and often this yield metrics are easier for team and other company
employees to relate with and understand.
IF there is known rework and it is significant to your team and company success, then
throughput yield and rolled-throughput yield are better metrics

Rolled Throughput Yield (RTY)

Rolled Throughput Yield is the probability of the entire process producing zero
defects. RTY is more important as a metric to use where the process has excessive
rework.
Since this rework involves many of the 7-wastes and contains the hidden factory
opportunity, it is relevant to guide the team in the right direction.
RTY is the product of each processs throughput yield, TPY.
Using the same process as shown in the TPY example:

Calculation from above example:

RTY = Process 1 TPY * Process 2 TPY * Process 3 TPY
RTY = 0.800 * 0.739 * 0.804
RTY = 0.475 = 47.5%
There is a 47.5% of the entire process producing zero defects.

RTY and other yield metrics can serve as baseline scores (Measure Phase) and final
scores for Six Sigma projects (Control Phase). The baseline score does not have to be
a z-score and often this yield metrics are easier for team and other company
employees to relate with and understand.
Another method to estimate RTY if the defects per unit or defects and units are
known:

Normalized Yield (NY)

Normalized yield is the average yield per process step. The probability of a unit passing
through one process step or opportunity without rework.
Formula:

where k equals the number of processes.

A calculation using example from above:

Calculation:
Using k = 3
NY = 0.475^(1/3)
NY = 0.780 = 78.0%
There is a 78% chance of a unit passing through one process step without rework.
Another relationship is shown below to obtain the normalized defects per unit.

The normalized defects per unit equals 0.2481.

Normalized Yield and other yield metrics can serve as baseline scores (Measure Phase)
and final scores for Six Sigma projects (Control Phase).
The baseline score does not have to be a z-score and often these yield metrics are
easier for team and other company employees to relate with and understand.