Analyzer Inputs
Example Data Table
| Date | Shift | Units | Defects | Scrap | Downtime (min) | Top Defect |
|---|---|---|---|---|---|---|
| 2026-03-01 | A | 1180 | 32 | 8 | 29 | Scratch / surface mark |
| 2026-03-01 | B | 1215 | 41 | 11 | 44 | Misalignment |
| 2026-03-02 | A | 1250 | 28 | 6 | 22 | Wrong label |
| 2026-03-02 | B | 1195 | 36 | 9 | 38 | Scratch / surface mark |
| 2026-03-03 | A | 1200 | 38 | 9 | 35 | Scratch / surface mark |
Formulas Used
- Defect Rate:
Defects ÷ Total Units - DPU:
Defects ÷ Total Units - DPMO:
(Defects ÷ (Units × Opportunities)) × 1,000,000 - First Pass Yield:
1 − Defect Rate - Final Yield:
1 − (Scrap Units ÷ Total Units) - Availability:
(Planned Time − Downtime) ÷ Planned Time - Performance:
(Ideal Cycle Time × Units) ÷ Run Time - Quality (OEE):
(Total Units − Scrap Units) ÷ Total Units - OEE:
Availability × Performance × Quality - Estimated Sigma: inverse normal of
(1 − DPMO/1,000,000)plus a shift. - Total Quality Cost:
(Scrap × Unit Cost × Multiplier) + (Rework × Rework Cost)
How to Use This Calculator
- Enter total units produced for the time window.
- Fill downtime, planned time, and ideal cycle time for OEE.
- Add scrap and rework to estimate quality cost impact.
- List defect types and counts to generate a Pareto focus.
- Click Analyze Production Issues to see metrics and actions.
- Use CSV/PDF downloads for reporting and audits.
FAQs
1) What does the severity score represent?
It combines defect rate, downtime, scrap, and rework into one 0–100 score. Higher scores mean bigger risk to throughput, cost, and customer quality.
2) Should I enter defects found or defect breakdown?
Use breakdown when you have counts by defect type. The analyzer uses breakdown totals and builds a Pareto table. If you only know total defects, enter the single defects value.
3) What are “opportunities per unit”?
It is the number of possible defect chances on one unit. For example, three critical checks equals 3 opportunities. Use 1 if you prefer a simple DPMO estimate.
4) How is sigma estimated here?
Sigma is approximated from DPMO using an inverse normal conversion, then a typical shift adjustment is applied. Treat it as a comparative indicator, not a certified capability result.
5) Why can performance exceed 100%?
If the ideal cycle time is slower than the actual run, calculated performance can exceed 100%. Re-check ideal cycle time and unit counts, then confirm the time window matches downtime data.
6) How do I interpret OEE with low quality loss?
A high quality percentage but low OEE often means availability or performance is the main constraint. Use downtime rate and cycle time accuracy to pinpoint whether stops or speed loss is dominant.
7) Does final yield assume all rework is successful?
Yes, final yield is simplified as total minus scrap. If rework sometimes fails, increase scrap units or adjust inputs to reflect the final disposition.
8) Can I use this for weekly or monthly reporting?
Yes. Keep the time window consistent, use the same defect naming, and track Pareto movement. When a defect type stays dominant, prioritize corrective action validation and prevention controls.