Analyze every process step with precision and speed. Reveal hidden yield losses before customers notice. Turn stage data into smarter quality improvement decisions today.
Enter your stage data below. After submission, the full result summary, downloadable exports, and Plotly chart will appear here above the form.
Use the controls below to model a full production or service process. The page stays single-column overall, while the calculator cards adapt to 3, 2, or 1 columns by screen size.
This example shows a four-stage process. It illustrates how first-pass yield differs from final yield after rework, and why RTY is usually lower than the simple final output rate.
| Stage | Units Entering | First-Pass Good | Rework Recovered | FPY % | Final Yield % |
|---|---|---|---|---|---|
| Incoming Inspection | 1000 | 985 | 8 | 98.50 | 99.30 |
| Cutting / Preparation | 993 | 975 | 10 | 98.19 | 99.19 |
| Assembly | 985 | 955 | 18 | 96.95 | 98.27 |
| Functional Test | 973 | 948 | 12 | 97.43 | 98.66 |
RTY focuses on first-pass success. Rework can improve shipped output, but it does not change first-pass process capability.
RTY measures the probability that a unit passes every stage correctly on the first attempt. It highlights hidden process loss better than simple final output because it penalizes each stage where defects or rework occur.
FPY describes one stage only. RTY multiplies all stage FPYs together, so it reflects the full process path. A line can show strong individual stages yet still have a disappointing RTY when losses compound.
Rework improves final shipped output, but it consumes time, labor, and capacity. Separating rework from first-pass good units shows whether performance came from a capable process or from expensive recovery activity.
Not always. Buffers, inspection holds, batch splitting, and rework loops can change stage input counts. Use the actual units entering each stage for the most realistic RTY, FPY, and DPMO calculations.
A strong target depends on process complexity, defect opportunities, and industry requirements. Stable, mature lines may target very high RTY, while new or complex lines focus first on improving the weakest stage drivers.
Final yield counts recovered units after rework. RTY only counts units that passed every step correctly the first time. That is why final yield can look acceptable while RTY still reveals costly process inefficiency.
DPMO normalizes defects against total defect opportunities. It is useful when stages differ in complexity, because one stage may have fewer units failing but far more possible defect points per unit.
Review RTY as often as decisions are made. High-volume operations may check every shift or hour, while lower-volume teams may review daily or weekly. Faster feedback shortens the time between defect creation and corrective action.
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.