Possible Solutions for Low First Pass Yield

3-5 Minutes to Read

Exploring Motivation as a Possible Solution for Low First-Pass Yield

Manufacturing organizations are constantly working to navigate disruptions. As the industry rebounds from the global pandemic and its associated labor shortages, production is finally starting to get back to normal. One of the best ways for these organizations to grow is to ensure that their finished product first-pass yield for primary products is calculated correctly. Focusing on motivation may be a great way to increase the first-pass yield to an acceptable range if it is low.

First-pass quality yield measures the percentage of finished products that meet quality specifications when arriving at a final test point. This metric is crucial for increasing efficiency and optimization, but it also helps minimize waste and improve resource consumption. Strong performance indicators in these areas will mean that employees are motivated, equipment is being maintained optimally, and fewer defects are created during the manufacturing process.

How Can Increased Motivation Improve Low First-Pass Yield?

Motivation is critical in any industry; however, the unique environment and job requirements in the manufacturing industry make it even more critical. According to research from APQC’s Open Standards Benchmarking database in manufacturing, the top manufacturing performers achieve roughly 98% success in meeting quality standards on a first pass. Alternatively, bottom performers tend to be around 8% lower – resulting in rework and increased scrap.

Any business seeking to achieve faster cycle times while reducing the generation of scrap should actively be nurturing the growth of their employees to make them top performers based on these statistics. And as you might have guessed, investing in motivational aspects could be the missing piece of the puzzle to achieve this. Some of the techniques that a manufacturing organization might consider when improving motivational processes company-wide include counseling, socialization, incentivization, or improved recognition programs. Top performers will actively neutralize low first-pass yield issues with these programs in place.

factory workers celebrating the success together

While motivation will often take care of the human side of low first-pass yield issues, the organization needs to ensure that positive momentum continues on the machine side as well. By using advanced analytics, manufacturing organizations can easily take control of their equipment up-time and regular maintenance without hindering their team members’ success. This data gives unmatched insight into decision-making processes but can also help a company quickly determine when a machine isn’t functioning as intended and dragging down processes. Any manufacturer that struggles with downtime should consider pursuing advanced analytics options.

Achieving top-tier performance for a first-pass yield shouldn’t be a challenge for manufacturers that have taken the time to plan accordingly, improve employee motivation, and streamline their processes. Any gaps throughout these areas will quickly deteriorate the possible level of success and may result in higher costs, decreased product quality, or lost efficiency.

If you struggle to maintain a positive workforce, Certified Source can help with our innovative performance-based staffing methods. We can help keep employee morale high with job-cycling opportunities that minimize monotonous work. Contact us today to learn what is possible for your manufacturing facilities!

Exploring Risk Management Programs as a Possible Solution for Low First-Pass Yield

If you are in the manufacturing industry, you likely already know how important a good first pass yield is for maintaining productivity and ensuring quality control. But what happens when you have a low first pass yield due to the unique risks associated with team members, the equipment utilized, or the materials required to complete the project? A risk management program to minimize potential injuries could help streamline processes and ensure the first pass yield reaches a projected range. Alternatively, financial risks could also potentially impact shareholder returns and result in a low first-pass yield.

Manufacturers interested in mitigating these risks need to have a solid risk management program that constantly evolves to improve processes and eliminate stressors that could negatively impact the project. Whatever the reason for understanding and controlling these risks, the leadership team at manufacturing facilities needs to have keen insight into comprehensive risk identification, risk measurement, risk assessment, risk monitoring, and risk minimization programs. Ideally, all would be addressed with one overarching risk management program adopted sitewide.

How Can Risk Management Programs Improve Low First-Pass Yield?

To implement an excellent risk management program, manufacturers will need to constantly ask questions, including "what are the potential risks, and which are most harmful?" and "What is the primary cause of these risks, and which are most likely to occur?" Management teams can have a pretty good idea of the risks affecting their first pass yield with this information. They can then use these answers to develop their risk management program that focuses on improving low first-pass yield.

One potential solution for ensuring that all bases are covered is to create a "risk team" within the organization that spans both management and the team members that the program implementation will affect. This allows for diverse views of the problems at hand and provides a nurturing environment for teamwork to make an effective plan. Over time, new risks will likely arise, and having those "boots on the ground" will help ensure that the program is continually monitored and tweaked to meet unique project goals.

Corporate business team and manager in a meeting
Corporate business team and manager in a meeting

As the risk assessment process continues, most manufacturers will pinpoint the bulk of the risks they face; however, they should also have a risk tool to identify their detectability, probability, and severity. By combining this data, a risk level number can be assigned to determine the acceptability of risk and prioritize potential risks that can be reduced effectively through new program changes. Although, it is essential to note that senior management will always need to play an active role in ensuring that required resources are provided.

Finally, it is recommended that each manufacturing facility that undergoes this process maintains an internal risk management file. This file should include tracking various hazards throughout the first pass yield process and identifying the risk analysis. And a record that risk was identified, detailing how risk controls will be implemented and verifying that the risk controls are acceptable – even if residual risks occur.

Exploring Setting, Tracking, and Monitoring Quality and Productivity Goals as a Possible Solution for Low First Pass Yield

Anyone focusing on productivity in a manufacturing setting likely already understands how important goal setting is for increased productivity. Dealing with low first pass yield requires careful planning, expert relationship management, investments in the right team members or technology, and well-documented processes and goals. But what role do setting, tracking, and monitoring quality and productivity goals play in improving first pass yield?

Quality first pass yield for primary products can help the percentage of products created during a production run that meet the quality specifications outlined by the manufacturing team. While there are countless reasons why a low first pass yield may occur, human error in the planning and creation processes is likely. Fortunately, establishing and maintaining quality and productivity goals is one of the easiest ways to counteract this all-too-common problem. Let’s look at some key ways that setting, tracking, and monitoring quality and productivity goals can help improve a low first pass yield.

How Can Quality and Productivity Goals Improve Low First Pass Yield?

Quality and productivity goals can take on many different forms. For instance, quality goals could relate to either the human aspect of your workforce or the material quality being used. At the same time, productivity goals could be modified simply by integrating new process documentation and training for your existing and upcoming workforce. The first step in utilizing quality and productivity goals to improve low first pass yield is to ensure that you know the root causes of why poor quality products are being created.

Setting, tracking, and monitoring quality and productivity goals can help address many problems that could be occurring within a manufacturing facility. When exploring this a little deeper, you might find that the process steps for your manufacturing systems are not accessible or adequately documented. This inherently makes it more difficult for newer employees to avoid common mistakes throughout the process, resulting in a much higher occurrence of defects. Skills, training, and documentation are crucial to quality and productivity goals; however, they are often overlooked when problems are seen.

Defining the quality and productivity goals that are most important for your facilities and taking the time to track and monitor them constantly will help address countless issues contributing to low first pass yield. Many leading companies have also started to take this a step further by utilizing predictive analytics and advanced AI to get real-time data about their equipment to improve cycle time, required costs, and achievable quality standards.

group of people tracking the goals and productivity

At Certified Source, we strive to help our manufacturing partners achieve a high first pass yield by sourcing the top talent available in their local markets and assisting in any training that might be required. To achieve this, these partners must ensure that their quality and productivity goals are outlined appropriately and documentation for necessary training has also been completed. With this information, our performance-based staffing experts can help make immediate positive impacts to help you achieve productivity goals and minimize waste.

Exploring the Development of Quality Teams as a Possible Solution for Low First Pass Yield

Before determining whether or not building quality teams is a possible solution for low first pass yields, it is essential to understand first past yields.

A first pass yield can be defined as the percentage of quality units produced compared to the amount that began the process. In other words, if a company had made 100 units but only 80 passed the quality assurance process (or were fully completed), the first pass yield would be 80%. First Pass Yield can also be known as throughput yield.

A company must maintain a high first pass yield for customer retention and a positive reputation. First pass yields can be considered whether a company is making a tangible product or providing a service. When first pass yields are low, the chances are that materials, labor, and time were wasted, meaning opportunities could be missed due to units not being up to standard.

When a company has an above-standard First pass yield, they are likely also to have a competitive advantage. Resources can be more effectively used, and customers will likely be much happier. There are a variety of factors that can lead to better first pass yield metrics. One of these is the development of quality teams. When a team is cohesive, focused, and delivers its product well, it is much more likely for its first pass yield percentage to rise.

How Can the Development of Quality Teams Eliminate Low First Pass Yield?

Many companies have experienced disruptions, particularly during the global pandemic. Whether these disruptions were labor shortages or manufacturing delays, they greatly affected businesses. Thankfully, there are some ways that companies can improve their practices to establish a higher first pass yield to optimize their processes.

Before developing an action plan, your team will want to determine the areas causing lower performance in the first place. Here is where creating a quality team, first and foremost, can come into play. When your team is united in its goals and the procedures and processes are in place to meet them, it is immediately more likely to have a higher first pass yield.

The team leader will want to make sure there are clear guidelines for the expectations of each employee and the team as a whole. This may include timelines for each step and documentation of the processes. Before starting any team processes, it would also be helpful to have quality training in place. When a team is created based on standard, consistent, communicated processes, troubleshooting problems is more straightforward. Consequently, when issues are addressed quickly and efficiently, there tends to be less waste, whether in materials or time.

Proper process management and adequate documentation can save a company time and resources. This, too, can contribute to the connectivity and consistency of your team. A team that works together and creates goals is likelier to deliver high first pass yield percentages.

Team leader discussing and brainstorming new approaches and ideas with colleagues

Certified Source makes it easy for employers to improve their first pass yield rates by helping to establish quality teams through staffing. Our programs allow qualified candidates to receive top-notch training, ensuring a positive impact upon their employment with a new company. Certified Source can swiftly connect you to top talent in the area, filling vacancies and enhancing your team. If you are ready to get started, find your nearest location to learn what is possible or contact us.