What is Manufacturing First Past Yield (FPY)?

Manufacturing First Past Yield (FPY) – The measure of product that is acceptably completed on the first attempt without requiring remedial action or rework.

To calculate the total manufacturing process FPY, have to multiply all sub section FPY between all sections.

Cutting FPY X Embellishment FPY X Sewing FPY X Washing FPY X Finishing FPY

First Past Yield = Output – Rework – Hold X 100

                                                    Output + Scrap

Note:

* Rework: Any pies which is reworked and returned to the process

* Holds: Input of one process which cant be passed on to the next process ( i.e. Remains as WIP for more than one day) due to lack of trims, awaiting of approvals, or similar problems should be treated as a “Hold” when it passes on to the next process

* Scrap: Any pies which is rejected and not returned to the process.

* Stock lots: If a stock lot is produced to order it should be captured as a part of output, if not it should be treated as Scrap.

hat is First Rejection Rate (FRR) ?

Quality level has calculated in terms of first rejections (FRR) and First Past Yield (FPY) calculation method has given to calculate the future quality levels as recommended.

First Rejection Rate (FRR) - The defects founded at the first time inspections.

Calculation method:

                        FRR = No of defects found X 100

                                     No of pcs checked

What is Financial Productivity?

Financial Productivity – The turnover achieved per employee expressed in US$

Calculation method:

                                    Turnover

                                 Total Headcount

Note:

* Express in US$

what is Man to Machine Ratio?

Man to Machine Ratio – The number of Employees per running machine

Calculation method:

                                Total Headcount              
                         Total no of machines used

Note:

* Total no of machines used: The average of the daily no of standard hours (SAH) generating machine operators (MO’s) present during the month

* Total Headcount: Closing Headcount for the month inclusive of casuals

What is Direct to Indirect Ratio?

Direct to Indirect Ratio – The number of Employees per Machine operator

Calculation method:

             Total Headcount - No of Machine operators
                             Total No of operators

Note:

* Total headcount should include the all management staff and workers

* No of operators should calculate including the Training machine operators (TMO) who are working in the sewing floor.

What is Receive to Ship Percentage?

Receive to Ship Percentage – The quantity of fabric shipped (in sq.yds) expressed as a percentage of fabric received (in sq.yds) for the reporting period.

Calculation method:

                            Total Shipped quantity (sq.yds) X 100     
                         Total fabric received for the orders (sq.yds)

Note:

* Express as a percentage
* Ship quantity in yards have to calculate, pcs shipped multiply by consumption
* Received fabrics have to obtain in square yards.

What is Receive to Ship Percentage?

Receive to Ship Percentage – The quantity of fabric shipped (in sq.yds) expressed as a percentage of fabric received (in sq.yds) for the reporting period.

Calculation method:

                                   Total Shipped quantity (sq.yds) X 100       
                                Total fabric received for the orders (sq.yds)


Note:
* Express as a percentage
* Ship quantity in yards have to calculate, pcs shipped multiply by consumption
* Received fabrics have to obtain in square yards.