(FTQ) is monitor and control of manufacturing process performance. First Time Quality (FTQ%) is a measure of the number of pieces first accepted in a manufacturing process versus the total number of pieces manufactured NOTE: Accepted Parts = It can be calculated at any stage of the manufacturing process when parts are accepted for the first time (rework is not included).
What is total quality management?
The goal of the business philosophy and approach known as “total quality management” is to maximize customer satisfaction. Total quality management is based on the principle that an organization can achieve long-term success if all of its members consistently strive to surpass quality expectations. The outcome should at the very least be a well-made product that satisfies the requirements of the company and its clients.
The main components or guiding principles of total quality management are as follows:
What is first-time quality?
First-time quality, also referred to as “first-time yield” and “first time right,” is a strategy for finishing a process without errors on the first try as well as a metric for gauging how successful this is. First-time quality is a method of total quality management with roots in the Six Sigma methodology, which aims to increase productivity and effectiveness. Due to its capacity to spot areas that require improvement and stop losses, it can be helpful in almost any industry. If it works, there will be little to no waste, little risk, and no need for replacements or additional work.
First-time quality is a metric that contrasts the process input and output. For example, if an apparel manufacturer produces 100 shirts per hour but five dont meet quality standards, the measure of first-time quality is 95%, with the remaining 5% being scrap First-time quality is a system made up of five steps, collectively referred to as DMAIC:
Benefits of first-time quality
The advantages of implementing first-time quality as a metric and system in your company include the following:
It helps to identify areas in need of improvement
Every process in an organization’s operations should ideally be measured for first-time quality, and the prevalence of defects can reveal which processes could use improvement. For instance, there are numerous production stages involved in the creation of clothing, such as pattern-making, cutting, bundling, sewing, pressing, and dyeing. If the stages of cutting, sewing, and dying seem to produce more scraps than the others, then it is clear that those areas require improvement.
It leads to faster resolution
You can take action to solve a problem more quickly if you can identify its root cause as soon as possible. The clothing manufacturer in the aforementioned example knows which steps in the production process need to be fixed, so it can start focusing resources on determining what’s causing the defects. Comparing the metrics of each system component should take much less time than analyzing just two stages of the production process.
It can measure process efficiency
Process efficiency measures how productive you are in relation to the time and money you invest in a process. A straightforward metric for measuring your production efficiency is first-time quality, which displays how many sellable items you produce per sample. Thus, if you have a first-time quality ratio of 80%, this gives you an idea of how much improvement you need to make to reach a more desirable level of efficiency
Tips for improving first-time quality
It’s crucial to determine which factors are affecting your yields and deal with the defects at their source because defects can have a variety of causes. In light of this, take into account the following advice for enhancing your first-time quality:
Check your raw materials
Your ability to produce high-quality goods can have a big impact on the final products you produce. Try to look at samples of your raw materials when you receive them because occasionally a supplier may have unintentionally let inferior materials pass to you. Finding and removing defective materials can help you avoid producing defective products in the future.
Maintain your machinery and equipment
If your raw materials meet requirements, your machinery or equipment might be the cause of any flaws. Despite being sophisticated, industrial tools gradually lose their accuracy and effectiveness, malfunctioning. You can resolve these with inspection and repair. Maintain your machines and equipment on a regular basis to make sure they work as intended. The additional advantage of routine maintenance is that it reduces waiting time waste brought on by equipment failure.
Practice proper process documentation
Process documentation is the ongoing process of gathering all the data and instructions required to carry out a business process. It’s crucial for first-time quality, especially when there is a change in personnel or when inexperienced workers take over an activity. The right documentation makes sure that everyone is aware of how to carry out the proper tasks in the correct order and manner to ensure consistent results, which prevents defects brought on by human error.
Right First Time Quality
FAQ
What is first time quality in manufacturing?
Calculation of the proportion of good parts at the start of a production run is known as first time quality (FTQ).
Do it right in quality first?
Doing the right thing the first time—and every time—is how you achieve quality. In this definition, “the right thing” is the customer’s requirement. Do the right thing (meet the customer’s requirement) correctly the first time is the organizational performance standard for delivering work.
What are the basic quality?
Establishing quality policy, quality objectives, quality planning, quality assurance, and quality improvement are some of these activities.
