{"id":92043,"date":"2026-05-02T07:16:50","date_gmt":"2026-05-02T07:16:50","guid":{"rendered":"https:\/\/teeptrak.com\/first-pass-yield-rty-multi-station-2026\/"},"modified":"2026-05-02T13:41:14","modified_gmt":"2026-05-02T13:41:14","slug":"first-pass-yield-rty-multi-station2026","status":"publish","type":"post","link":"https:\/\/teeptrak.com\/en\/first-pass-yield-rty-multi-station2026\/","title":{"rendered":"First Pass Yield & RTY for Multi-Station Lines (2026)"},"content":{"rendered":"

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First Pass Yield & RTY for Multi-Station Manufacturing Lines<\/h1>\n
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TL;DR<\/strong><\/p>\n

First Pass Yield (FPY) measures the percentage of parts passing inspection on the first attempt at a single station. Rolled Throughput Yield (RTY) is the product of all individual station FPYs across a multi-station line. Small per-station improvements compound massively: going from 95% to 99% per station improves overall yield from 77% to 95% on a 5-station line. This guide covers the formulas, station-level analysis methodology, and improvement approach.<\/p>\n<\/div>\n

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First Pass Yield (FPY) is the percentage of parts passing inspection on the first attempt at a single station; Rolled Throughput Yield (RTY) is the product of all individual station FPYs.<\/strong><\/p>\n<\/div>\n

First Pass Yield (FPY) measures the percentage of parts passing inspection on the first attempt, without rework or retesting.<\/strong><\/p>\n

FPY is closely related to OEE Quality but more granular \u2014 FPY is typically tracked per inspection station, while OEE Quality is at line level. For multi-station lines, you need both FPY (per station) and RTY (rolled across all stations).<\/p>\n

FPY definition (1-sentence)<\/h2>\n

FPY = Parts Passing First Inspection \u00f7 Total Parts Inspected, expressed as a percentage.<\/strong><\/p>\n

Critical: “Parts Passing First Inspection” excludes anything that needed rework, retesting, or downgrades.<\/strong> A part that fails initial inspection but passes after rework is NOT a first-pass success.<\/p>\n

RTY for multi-station lines<\/h2>\n

RTY = product of all individual station FPYs across a multi-station line.<\/strong><\/p>\n

Worked example. A 5-station line with 99% FPY at each station has:<\/p>\n

RTY = 0.99\u2075 = 0.951 = 95.1%<\/strong><\/p>\n

A 5-station line with 95% FPY at each station has:<\/p>\n

RTY = 0.95\u2075 = 0.774 = 77.4%<\/strong><\/p>\n

The compounding effect is dramatic. Going from 95% to 99% per station \u2014 a 4-point per-station change \u2014 improves overall yield from 77% to 95% (18-point gain).<\/p>\n

Why per-station improvements compound<\/h2>\n

RTY is a multiplicative measure \u2014 small per-station improvements have outsized aggregate impact.<\/strong><\/p>\n\n\n\n\n\n
Per-station FPY<\/th>\nRTY (5 stations)<\/th>\nRTY (10 stations)<\/th>\n<\/tr>\n
90%<\/td>\n59%<\/td>\n35%<\/td>\n<\/tr>\n
95%<\/td>\n77%<\/td>\n60%<\/td>\n<\/tr>\n
99%<\/td>\n95%<\/td>\n90%<\/td>\n<\/tr>\n<\/table>\n

For long lines (10+ stations), the difference between 95% and 99% per station is the difference between 60% and 90% overall yield.<\/p>\n

FPY benchmarks by industry<\/h2>\n
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  • Automotive OEM:<\/strong> median 94%, world-class 98%<\/li>\n
  • Food & beverage:<\/strong> median 94%, world-class 97%<\/li>\n
  • Pharma biologics:<\/strong> median 97%, world-class 99% (highest, GMP)<\/li>\n
  • Electronics & semiconductors:<\/strong> median 95%, world-class 98%<\/li>\n
  • Plastics extrusion:<\/strong> median 92%, world-class 96%<\/li>\n<\/ul>\n

    4-level FPY tracking maturity<\/h2>\n
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    1. Level 1:<\/strong> Aggregate FPY at end of line, monthly. Useful for trends; too late for action.<\/li>\n
    2. Level 2:<\/strong> Daily FPY at end of line with defect categories. Pareto possible; no station-level diagnosis.<\/li>\n
    3. Level 3:<\/strong> Real-time FPY per station with defect tagging. Enables station-level RTY analysis.<\/li>\n
    4. Level 4:<\/strong> Automated defect classification + closed-loop RCA action items.<\/li>\n<\/ol>\n

      How to improve RTY (4-step methodology)<\/h2>\n
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      1. Measure RTY by station.<\/strong> Identify the worst station \u2014 typically the bottleneck for overall yield.<\/li>\n
      2. Pareto defect categories at the worst station.<\/strong> Top 3 defect types representing 60-80% of failures.<\/li>\n
      3. RCA on top 3.<\/strong> 5-Why or Ishikawa, action items tracked to closure.<\/li>\n
      4. Verify at 30 days.<\/strong> If top defect dropped, move to next station. If not, RCA was incomplete.<\/li>\n<\/ol>\n

        Plants implementing structured RTY improvement typically gain 2-4 OEE points within 6 months.<\/p>\n

        Watch: How TeepTrak Customers Transform OEE<\/h2>\n