Process control chart or Run chart

Process charts determines the critical operations in the process and

when inspection might be needed. Because there are some part of
operations, which, if performed incorrectly can lead to defective
output.
It also determines the critical product or process, which are
attribute of the product that will result in good on poor function of
process.
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Rolled Throughput Yield - RTY
Rolled Throughput Yield (RTY) is the probability that a single unit can pass through a series of
process steps free of defects.

Next we will turn our attention to a Rolled Throughput Yield example. If you will remember, the
First Time Yield calculation we did (FTY) considered only what went into a process step and
what went out. Rolled Throughput Yield adds the consideration of rework. Using the previous
example:

Process A = 100 units in and 90 out Process B = 90 in and 80 out Process C = 80 in and 75
out Process D = 75 in and 70 out.

If in order to get the yield out of each step we had to do some rework (which we probably did)
then it really looks more like this:

Process A = 100 units, 10 scrapped and 5 reworked to get the 90. The calculation becomes
[100-(10+5)]/100 = 85/100 = .85 This is the true yield when you consider rework and scrap.

Process B = 90 units in, 10 scrapped and 7 reworked to get the 80. [90-(10+7)]/90 = .81

Process C = 80 units in, 5 scrapped and 3 reworked to get the 75. [80-(5+3)]/80 = .9

Process D = 75 units in, 5 scrapped and 10 reworked to get the 70. [75-(5+10)]/75 = .8

Now to get the true Rolled Throughput Yield (Considering BOTH scrap and the rework
necessary to attain what we thought was first time throughput yield) we find that the true yield
has gone down significantly:

.85*.81*.9*.8 = .49572 or Rounded to the nearest digit, 50% yield. A substantially worse and

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substantially truer measurement of the process capability. An Assumption is made in the

preceeding example that there are no spilled opportunities after each process step

Sigma to DPMO to Yield to Cpk Table

Sigma DPMO Yield Cpk
1.5 500,000 50% 0.50
3.00 66,800 93.320% 1.00
3.50 22,700 97.730% 1.17
4.00 6,210 99.3790% 1.33
4.50 1,350 99.8650% 1.50
5.00 230 99.9770% 1.67
 6.00 3.4 99.99966% 2.00
Assumptions
No analysis would be complete without properly noting the assumptions made. In the above
table, we have assumed that the standard sigma shift of 1.5 is appropriate (the calculator
allows you to specify another value), the data is normally distributed, and the process is
stable. In addition, the calculations are made with using one-tail values of the normal
distribution.

Related > How to Calculate Process Sigma

Related > Sigma To Cpk Conversion Table

Discussion
If you are starting with DPMO, convert it to a decimal value by dividing by 1,000,000. If you
multiply that decimal by 100, that is your Yield (%). If you take the decimal and look it up in a
standard normal curve (Z table), you can determine the corresponding Z which is the long
term Z. To convert to short term Z, which is the Sigma level, use the following formula:

Z(short term) = Z(long term) + 1.5

Then you can determine Cpk using the following formula:

Cpk = Z(short-term) / 3

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Sigma To Cpk Conversion Table

Sigma Cpk
1.5 0.50
3.00 1.00
3.50 1.17
4.00 1.33
4.50 1.50
5.00 1.67
6.00 2.00
Assumptions
No analysis would be complete without properly noting the assumptions made. In the above
table, we have assumed that the standard sigma shift of 1.5 is appropriate (the calculator
allows you to specify another value), the data is normally distributed, and the process is
stable. In addition, the calculations are made with using one-tail values of the normal
distribution.