Direct answer
First-pass yield is the percentage of units that meet the finished standard through the process without rework. Define the start and end point, count rework consistently, trace defects to the originating station and use the result alongside output and waste so problems are not hidden by later correction.
Define a good first-pass unit
A unit passes first time only when it completes the defined process without correction, relabelling, refill, recap, reseal, manual sorting or repeat inspection. State whether start-up packs and samples are included.
Use one definition across shifts so the trend reflects the process rather than reporting preference.
Record the originating defect
A carton rejected at the end may have been caused by an earlier fill, cap, label or code fault. Record both detection point and likely origin.
Separate material defects, equipment faults, settings, operator handling and unknown causes.
Avoid hiding loss in rework
A high final good-output figure can coexist with poor first-pass yield when many packs are corrected. Rework consumes labour, capacity and traceability attention and can introduce new defects.
Track rework hours and material loss beside FPY.
Use FPY to verify improvement
Measure a baseline over representative products and shifts, change one process factor and compare enough output to show a stable result.
Review FPY by SKU and format; a site-wide average can hide one difficult pack.
Information to prepare
- Defined process start and finish
- Clear first-pass acceptance standard
- Consistent treatment of rework and start-up packs
- Defect code and originating station
- Good, reworked, scrapped and held counts
- Trend by SKU, shift and machine
- Action and verification record
Packaging Automation UK
Automation and inspection routes for improving right-first-time packaging output.