See the hidden "factory within a factory" that consumes your capacity. Visual proof of why 10% rework costs far more than 10%.
See It In ActionWatch defective parts cycle back through the system, consuming capacity that should be making new product
"90% first pass yield means we lose 10% to rework. That's not so bad."
Each reworked unit consumes capacity twice. Some fail again. A 10% defect rate can consume 20-40% of your effective capacity.
Fix root causes, not symptoms. One percentage point of FPY improvement often beats adding a second shift.
But it's actually worse: reworked items can fail again. With 90% FPY, you process an average of 1.11 units for every 1 that ships. That's 11% overhead just from the first rework cycle.
World-class FPY is typically 95% or higher, but "good" depends on your industry and process complexity. The key insight is that even small FPY improvements have outsized capacity benefits due to the multiplier effect of rework.
Simple formula: if FPY = 90%, you process 1/(0.90) = 1.11 units on average per shipped unit. But this compounds if reworked items can fail again. The simulation shows the full dynamic effect.
Common causes include operator error, equipment drift, material variation, unclear work instructions, and process capability issues. The simulation helps you see the impact before deciding where to invest in improvements.
No signup required. Watch capacity disappear in real-time.
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