Rolled Throughput Yield (RTY) is an important metric used in quality management and process improvement. It is a measure of the effectiveness of a manufacturing process over time and can be used to identify problems that may be hindering the production of a good product. RTY can be an invaluable tool for manufacturers, helping them to identify problems early, reduce costs associated with production, and ultimately improve the quality of their products. In this blog post, we’ll be taking a closer look at RTY and discussing the benefits it can bring to manufacturing processes. We’ll also discuss how manufacturers can calculate the RTY of their processes and use this information to make improvements. Finally, we’ll discuss the importance of maintaining an RTY that is acceptable to the customer. By the end of this blog post, you should have a better understanding of RTY and how it can help you improve your manufacturing process.
Who uses rolled throughput yield?
This metric can be used to gauge the effectiveness of operations by those looking to improve their business processes. Particularly, the Six Sigma methodology, which encourages lean business operations, uses RTY as a metric. This approach defines a lean business as one that encourages maximizing profits while reducing waste. Waste can be:
RTY measures defects in a product. One of many steps provided by the Six Sigma method to reduce waste is eliminating this source of waste.
What is rolled throughput yield?
When comparing the quantity of goods produced on a production line to the total number of goods produced, rolled throughput yield (RTY), a metric, is used. Yield is the quantity of goods produced at a particular time. The term “throughput” refers to all goods that have been fully produced and satisfy the requirements necessary for the seller to accept them.
In the past, manufacturers only calculated the throughput by subtracting the number of defective products from the total yield at the end of production. However, this approach ignores the use of subpar materials throughout the production process. When calculating how much product the manufacturing team scrapped due to subpar quality or manufacturing, RTY takes those materials into consideration.
How is rolled throughput yield used?
RTY is a component of the Six Sigma approach, an operational framework for enhancing business procedures. The goal of Six Sigma is to reduce waste and streamline processes. The following are some ways that RTY can help your manufacturing processes get better:
Identify the hidden factory
When a product has a flaw, processes that take place away from the assembly line are referred to as the “hidden factory.” When a worker discovers a flaw, they may take the product off the line to fix it and find a solution before putting it back on the production line. As a result, that employee and product are subject to a second set of procedures and operations. The term “hidden factory” refers to these additional processes.
To reduce time loss, you can identify these processes using RTY. RTY can also be used to pinpoint the areas of defects that need to be fixed by additional procedures. Process streamlining can also be accomplished by addressing the source of the flaws.
Reveal faulty material
You can determine where in your process the greatest number of defects are occurring by reviewing your RTY. For example, a soccer ball manufacturer may have a 100% yield after the first process of sewing the leather exterior of soccer balls This demonstrates that there isn’t a glaring issue with the leather’s quality. However, a 50% yield after stuffing the interior of the soccer ball can show that the stuffing isnt providing quality that meets their standards
Your RTY can help you identify process delays brought on by subpar materials or workmanship. By changing your procedure to address these flaws, you can raise output and profit.
Track improvement over time
As you tweak your procedure, you can use your RTY number to track your progress. You can check to see if you have correctly identified the cause of the defects or the lost time by routinely calculating your yield. Additionally, you can assess your level of development and the efficacy of your streamlining strategies.
How is rolled throughput yield calculated?
You can calculate RTY using the following steps:
1. Calculate the yield for each unique process
You can determine the yield for each procedure your product goes through during production. You can calculate yield using this equation:
Yield is determined by dividing the number of units that can be produced by the number of acceptable units.
For instance, the same manufacturer of soccer balls can determine the yield at each of the three stages of production. They begin with 5,000 soccer balls entering production. After the first process, employees scrap 100 leather exteriors. The yield for the first process is:
Yield = 4,900 / 5,000
Yield = 0.98 or 98%
1,600 partially stuffed soccer balls are defective and scrapped during the second process. The yield for the second process is:
Yield = 3,300 / 4,900
Yield = 0.67 or 67%
Thirdly, 3,250 soccer balls that have finished their exterior design pass quality inspection. The yield for the third process is:
Yield = 3,250 / 3,300
Yield = 0.98 of 98%
2 Consider reworks
Finding out how many of your products are making it through production by calculating yield is a great idea. However, yield doesn’t take into account how many of the items that pass through the assembly line were initially flawed, fixed in the covert factory, and then re-assembled. Rework is what businesses refer to it as, and it can put a strain on your labor force. If you don’t know this information, you might overlook a flaw in your process that your workers are compensating for by devoting energy away from the assembly line and toward other processes.
You can do this by calculating the throughput yield:
Throughput yield = # of quality units completed with no rework / total units entering production.
3. Combine throughput yields into your rolled throughput yield
Your rolled throughput yields can now be created by combining the throughput yields for each of your processes. There are two ways to do this, depending on how your manufacturing processes are set up:
In a linear manufacturing line, a serial process is when one process flows into another. For instance, the manufacturing of soccer balls uses a serial process because each step feeds into the next and cannot occur simultaneously. Where TPY stands for throughput yield, the equation for a serial process is:
RTY is equal to the sum of processes 1 through 3 (TPY).
You can multiply as many TPY as you have processes. the RTY for the soccer ball manufacturing company might be:
RTY = 80% x 60% x 99%
RTY = 48%
When several processes run concurrently, that is a parallel process. These can be independent processes or processes that feed into the same assembly line in subsequent processes. By figuring out the minimum throughput yield for these processes, you can calculate the rolled throughput yield. Here is the equation:
RTY equals the minimum of processes 1 through 3 (TPY).
For instance, if the company that makes soccer balls also has an assembly line for making footballs, those processes would go hand in hand. In this illustration, the first step in making a football also entails sewing the leather exterior, albeit in a different pattern. The first stage of this production line would have the following throughput yield if 6,000 footballs entered production and only 4,500 footballs were to leave it:
Throughput yield = 0.75 or 75%
The RTY for both production lines’ first process would be:
RTY = min (80%, 75%)
RTY = 75%
Calculating the Rolled Throughput Yield (RTY) | Lean Six Sigma Complete Course.
FAQ
Why is rolled throughput yield?
- Yield 1 times Yield 2 times equals Rolled Throughput Yield.
- My processes are working at a nice 95% first pass yield rate, but my rolled throughput rate is just under 60%
- My rolled throughput yield is 100%.
How do you calculate throughput yield?
A process performance metric called Rolled Throughput Yield (RTY) offers insight into the overall process’s cumulative effects. RTY calculates the likelihood that a unit will complete a process step without any defects by measuring the yield for each of several process steps.
What is the difference between first time yield and rolled throughput yield?
When calculating throughput yield, only the units that pass the process without rework or scrap are counted. YRT = YTP at step 1 * YTP at step 2 * YTP at step 3 using the example above. Consequently, the label process’s rolled throughput yield is 0. 95 * 0. 84 * 0. 88 = 0. 70.
