首次通过率管控 Right First-time pass rate control

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首次通过率（First Pass Yield, FPY 或 First Time Throughput, FTT）是衡量生产过程效率和质量稳定性的核心关键绩效指标（KPI）。它反映了产品或服务在不经过返工、修复或报废的情况下，一次性通过所有必要工序或检验的比例。

有效管控首次通过率，是减少浪费、降低成本、提升交付能力和客户满意度的关键。

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First Pass Yield (FPY or First Time Throughput, FTT) is a core key performance indicator (KPI) for measuring the efficiency and quality stability of production processes. It reflects the proportion of products or services that pass all necessary procedures or inspections without requiring rework, repair, or scrapping in a single attempt.

Effectively managing the first-time pass rate is key to reducing waste, lowering costs, enhancing delivery capability, and improving customer satisfaction.

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首次通过率的定义与计算
定义：在指定的生产或服务流程中，首次通过所有检验点而无需返修或报废的产品数量，占总投入产品数量的百分比。
基本公式：
首次通过率 (FPY) = (首次通过的产品数量 / 总投入产品数量) × 100%
多工序流程的计算（更精确）：
如果一个流程包含多个独立工序，整体首次通过率是各工序首次通过率的乘积。
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整体FPY = FPY₁ × FPY₂ × FPY₃ × ... × FPYₙ
示例：一个产品经过3道工序。
工序1：投入100件，95件合格 → FPY₁ = 95%
工序2：投入95件，90件合格 → FPY₂ = 94.7%
工序3：投入90件，88件合格 → FPY₃ = 97.8%
整体FPY = 95% × 94.7% × 97.8% ≈ 88.1%
意义：即使每道工序的合格率都很高，累积的损失也会显著降低整体效率。

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Definition and Calculation of First Pass Rate
Definition: The percentage of products that pass all inspection points for the first time in a specified production or service process without the need for repair or scrapping, as a percentage of the total number of products invested.
Basic formula:
First pass rate (FPY)=(number of products passed for the first time/total number of products invested) x 100%
Calculation of multi process flow (more accurate):
If a process contains multiple independent processes, the overall first pass rate is the product of the first pass rates of each process.
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Overall FPY=FPY ₁× FPY ₂× FPY ③× .. × FPYₙ
Example: A product goes through three processes.
Process 1: Input 100 pieces, 95 pieces are qualified → FPY ₁=95%
Process 2: Input 95 pieces, 90 pieces qualified → FPY ₂=94.7%
Process 3: Input 90 pieces, 88 pieces qualified → FPY ∝=97.8%
Overall FPY=95% × 94.7% × 97.8% ≈ 88.1%
Meaning: Even if the pass rate of each process is high, the accumulated losses will significantly reduce overall efficiency.

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管控首次通过率的重要性
益处        说明
降低成本        减少返工、报废、额外检验和人力成本。
提高生产效率        减少流程中断和等待时间，提升设备和人力利用率。
缩短交付周期        产品一次性通过，无需等待返修，更快交付客户。
提升客户满意度        减少因返修导致的交付延迟和潜在的质量波动。
暴露过程问题        FPY低是过程不稳定或存在缺陷的“晴雨表”，驱动持续改进。
支持精益生产        是衡量“精益”程度的重要指标，与“零缺陷”理念一致。

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The importance of controlling the first pass rate
Benefit Explanation
Reduce costs by minimizing rework, scrapping, additional inspections, and labor costs.
Improve production efficiency, reduce process interruptions and waiting times, and enhance equipment and manpower utilization.
Shorten the delivery cycle by allowing products to pass in one go without waiting for repairs, resulting in faster delivery to customers.
Improve customer satisfaction and reduce delivery delays and potential quality fluctuations caused by rework.
Low FPY during the exposure process is a barometer of unstable or defective processes, driving continuous improvement.
Supporting lean production is an important indicator for measuring the degree of "lean", consistent with the concept of "zero defects".

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首次通过率管控的核心步骤1. 建立清晰的流程与标准

• 定义“首次通过”：明确哪些环节需要计算FPY（如关键工序、最终检验）。
• 标准化作业：制定并执行标准作业程序（SOP），确保操作一致性。
• 明确检验标准：检验标准必须清晰、可量化，避免主观判断。
  

2. 数据收集与监控

• 实时记录：在每个关键工序或检验点，记录“投入数”、“合格数”、“不合格数”、“返工数”、“报废数”。
• 自动化采集：利用MES（制造执行系统）、SCADA或条码系统自动采集数据，提高准确性和及时性。
• 可视化看板：在车间设置FPY看板，实时展示各工序/产线的FPY，增强透明度。
  

3. 分析与根本原因调查

• 趋势分析：绘制FPY趋势图，识别下降或波动的时间点。
• 分层分析：
  • 按产品型号：哪个型号FPY低？
  • 按生产线/班组：哪个产线或班组表现差？
  • 按时间段：是否在换班、开机时FPY下降？
  • 按缺陷类型：最常见的缺陷是什么？
    
• 根本原因分析（RCA）：对FPY低的环节，使用5 Why、鱼骨图、FMEA等工具，找出根本原因（人、机、料、法、环、测）。
  

4. 制定并实施改进措施

• 针对性改进：根据RCA结果采取措施，例如：
  • 人：加强培训、技能认证。
  • 机：设备维护、参数优化、防错装置（Poka-Yoke）。
  • 料：加强来料检验、供应商管理。
  • 法：修订SOP、优化工艺流程。
  • 环：改善工作环境（温湿度、照明）。
  • 测：校准检验设备、优化检验方法。
    
• 小范围试点：在全面推广前，先进行小批量验证。
  

5. 效果验证与标准化

• 跟踪FPY变化：措施实施后，持续监控FPY，确认是否提升并稳定。
• 固化成果：将有效的改进措施纳入SOP、培训教材或设备设置中，防止问题复发。
  

6. 建立闭环管理机制

• 将FPY纳入日常管理会议（如早会、周会）的固定议题。
• 设定FPY目标值，并与团队绩效挂钩。
• 定期进行管理评审，回顾FPY表现和改进项目。
  

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The core steps of first pass rate control
1. Establish clear processes and standards
Definition of 'first pass': Identify which steps require FPY calculation (such as critical processes, final inspection).
Standardized operations: Develop and implement standard operating procedures (SOPs) to ensure operational consistency.
Clear inspection standards: Inspection standards must be clear, quantifiable, and avoid subjective judgments.
2. Data collection and monitoring
Real time recording: Record the "input quantity", "qualified quantity", "unqualified quantity", "rework quantity", and "scrap quantity" at each key process or inspection point.
Automated data collection: Utilizing MES (Manufacturing Execution System), SCADA, or barcode systems to automatically collect data, improving accuracy and timeliness.
Visual Kanban: Set up FPY Kanban in the workshop to display the FPY of each process/production line in real time, enhancing transparency.
3. Analysis and Root Cause Investigation
Trend analysis: Draw an FPY trend chart to identify time points of decline or fluctuation.
Hierarchical analysis:
By product model: Which model has lower FPY?
By production line/team: Which production line or team performs poorly?
By time period: Does FPY decrease during shift change or startup?
By defect type: What is the most common defect?
Root Cause Analysis (RCA): For areas with low FPY, use tools such as 5 Why, fishbone diagram, FMEA, etc. to identify the root cause (human, machine, material, method, environment, measurement).
4. Develop and implement improvement measures
Targeted improvement: Take measures based on RCA results, such as:
Person: Strengthen training and skill certification.
Machine: equipment maintenance, parameter optimization, error prevention device (Poka Yoke).
Material: Strengthen incoming material inspection and supplier management.
Method: Revise SOP and optimize process flow.
Environment: Improve the working environment (temperature, humidity, lighting).
Testing: Calibrate inspection equipment, optimize inspection methods.
Small scale pilot: Conduct small-scale verification before comprehensive promotion.
5. Effectiveness verification and standardization
Tracking FPY changes: After implementing measures, continuously monitor FPY to confirm if it has improved and stabilized.
Solidify results: Incorporate effective improvement measures into SOPs, training materials, or equipment settings to prevent problem recurrence.
6. Establish a closed-loop management mechanism
Include FPY as a fixed topic in daily management meetings (such as morning and weekly meetings).
Set FPY target values and link them to team performance.
Regularly conduct management reviews to review FPY performance and improvement projects.

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升首次通过率的关键策略

• 推行防错（Poka-Yoke）：在流程中设计自动检测和防止错误发生的装置，从源头拦截缺陷。
• 加强过程能力分析（CPK）：确保关键工序的过程能力指数（CPK）达标，过程稳定受控。
• 实施全面生产维护（TPM）：减少设备故障导致的缺陷。
• 开展质量圈（QCC）活动：鼓励一线员工参与问题解决。
• 利用数字化工具：通过SPC（统计过程控制）实时监控过程，AI预测潜在异常
  

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Key strategies to improve first pass rate
Poka Yoke: Design automatic detection and error prevention devices in the process to intercept defects from the source.
Strengthen Process Capability Analysis (CPK): Ensure that the Process Capability Index (CPK) of critical processes meets standards and the process is stable and controlled.
Implement Total Productive Maintenance (TPM): Reduce defects caused by equipment failures.
Carry out Quality Control Circle (QCC) activities: Encourage frontline employees to participate in problem-solving.
Utilizing digital tools: Real time monitoring of processes through SPC (Statistical Process Control) and AI prediction of potential anomalies