Analyze every stage before defects multiply across operations. Visualize yield, scrap, and hidden factory losses. Turn stage data into stronger engineering and quality actions.
Use the responsive stage grid below. The page remains single-column while the stage inputs adapt to screen size.
| Stage | Units Entering | Defective Units | Reworked Units | Scrapped Units |
|---|---|---|---|---|
| Cutting | 1000 | 20 | 8 | 6 |
| Machining | 980 | 15 | 6 | 4 |
| Welding | 965 | 12 | 5 | 3 |
| Assembly | 950 | 10 | 4 | 2 |
| Inspection | 940 | 5 | 2 | 1 |
You can load the form with similar values, then test how defect reductions at one stage improve total rolled throughput yield.
Stage First-Pass Yield:
FPYi = (Units Ini − Defective Unitsi) / Units Ini
Rolled Throughput Yield:
RTY = FPY1 × FPY2 × FPY3 × ... × FPYn
Defects per Unit:
DPU = Defective Units / Units In
Defects per Million Opportunities:
DPMO = (Defective Units × 1,000,000) / (Units In × Opportunities per Unit)
RTY measures the chance that one unit passes the entire process without needing defect correction. Reworked units are tracked for cost and visibility, but they do not increase first-pass yield.
It shows the probability that one unit passes every stage without defects. Unlike simple average yield, it reflects compounding losses across the full process chain.
Each stage loss multiplies with earlier losses. Even strong individual yields can produce a much lower overall result when many stages are connected.
No. RTY measures first-pass success only. Reworked units are still useful for cost analysis, but they do not improve first-pass stage yield.
The bottleneck stage is the stage with the lowest first-pass yield. Improving it often provides the biggest lift in total rolled throughput yield.
DPMO standardizes defect levels against opportunities for error. It helps compare stages or processes with different unit counts and complexity levels.
Yes. Any multi-step engineering or operational process can use RTY, including assembly, testing, maintenance workflows, fabrication, and service operations.
They estimate the cost of poor quality from the current sample. This helps connect yield losses to financial impact and prioritization decisions.
Start with the lowest-yield stage, reduce its root-cause defects, and repeat the calculation. Small improvements at weak points often create meaningful total gains.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.