Calculator
Example data table
| Run | Total units | Good units | Defective | Reworked | Planned min | Run min | Ideal sec/unit |
|---|---|---|---|---|---|---|---|
| A | 1200 | 1146 | 38 | 16 | 480 | 445 | 18.0 |
| B | 850 | 811 | 31 | 8 | 360 | 340 | 22.5 |
| C | 1500 | 1473 | 19 | 8 | 600 | 585 | 16.2 |
Formulas used
Yield (%) = (Good Units ÷ Total Units) × 100
Availability (%) = (Run Time ÷ Planned Time) × 100
Performance (%) = (Ideal Time for Total Units ÷ Run Time) × 100
Ideal Time for Total Units (min) = (Ideal Cycle Time (sec) × Total Units) ÷ 60
Quality (%) = (Good Units ÷ Total Units) × 100
OEE-style Composite (%) = Availability × Performance × Quality
Production Efficiency Yield (PEY) (%) = Yield × Availability × Performance
How to use this calculator
- Enter total and good units from your production record.
- Add defective and reworked units for deeper loss tracking.
- Provide planned minutes and run minutes for time-based efficiency.
- Enter ideal cycle time if you track standard work.
- Press Submit to view PEY, yield, and indicators.
- Download CSV or PDF for reporting and audits.
Operational notes
Operational benchmarks for yield
Yield converts accepted units into a percentage of total output. Mature lines often target 98%+ on stable products. Track yield by shift and lot, then compare against the same product family. When yield drops, pair the change with defect codes, rework tickets, and operator notes to isolate the cause.
Defect and rework signals you can quantify
Defect rate and rework rate help separate scrap loss from recoverable loss. For example, a 3.0% defect rate with a 1.0% rework rate implies most failures are not returning to saleable inventory. If rework rises above 2% for days, validate fixtures and incoming checks. These indicators support targeted containment, not just a single headline number.
Time losses captured through availability
Availability compares run time to planned time, exposing downtime and changeover impacts. A practical daily goal is 85% to 95% depending on product mix and maintenance strategy. If availability falls below 80%, review stoppage logs: micro-stops, jams, and waiting on materials typically dominate. Improving availability protects scheduled capacity.
Performance and ideal cycle discipline
Performance evaluates how closely actual speed matches the ideal cycle. When performance is under 90%, confirm the ideal cycle time reflects current tooling and staffing. Use short interval control: compare expected units per hour to actual throughput and annotate the gap. Small improvements, like stabilizing feeder flow, can lift performance without new equipment.
Composite view with OEE-style efficiency
The composite multiplies availability, performance, and quality to show the combined effect of losses. A score above 70% is often strong for mixed-model lines; high-volume automation may target 80%+. Use the components to explain the score: a solid composite with weak quality can still hide customer risk. Align actions to the lowest component for faster recovery.
How PEY supports quality-driven decisions
Production Efficiency Yield (PEY) keeps yield central while scaling it by time efficiency, making it useful for daily reviews. Two lines can share the same yield, yet one may produce less because of downtime or slow cycles; PEY highlights that difference. Report PEY by product and week, then link changes to corrective actions and verification results. Use the chart to review PEY alongside yield, then confirm improvements with audit-ready downloads for supervisors and customers in weekly ops reviews.
FAQs
1) What does PEY represent in one sentence?
PEY is yield adjusted by time efficiency, reflecting accepted output while accounting for downtime and speed losses in one percentage.
2) Do defective units need to equal total minus good?
Not necessarily. Total and good drive yield. Defective and reworked values are optional diagnostics and can be tracked separately if your process records them in parallel.
3) What if I don’t know the ideal cycle time?
Leave it blank, but performance will be near zero. Use a validated standard cycle from engineering, or estimate from best stable runs and refine later.
4) Why validate run time against planned time?
Run time longer than planned usually indicates a mismatch. Keeping run time at or below planned time avoids inflated availability and makes comparisons consistent.
5) Which metric should I improve first?
Start with the weakest component: quality for defects, availability for downtime, or performance for speed. Improving the constraint component typically lifts PEY fastest.
6) Can I use this for multiple lines or shifts?
Yes. Enter each run’s totals and times, download the CSV or PDF, and compare results across lines, shifts, products, and weeks using the same definitions.