Direct answer
First-pass yield is the proportion that meets requirements without rework on the first pass. Reject rate shows failed output, but can be misleading if reworked units are later counted as good without recording the original defect. Track defect type and first point of creation as well as the final count.
Practical objective: a quality measure that exposes where defects are created and how much capacity, labour and material they consume.
Questions and phrases customers use
This guide also answers searches such as:
- first pass yield calculator
- packaging reject rate
- production yield quality
- rework rate manufacturing
Information to collect first
Use one controlled set of figures and representative production conditions. Record the source and date of each assumption so quotations and improvement options can be compared on the same basis.
- Define a good unit and the inspection boundary
- Count total units entering the process, first-pass good units, rework and scrap
- Prevent double counting when reworked units re-enter the line
- Classify defect type and production step where it originated
- Segment results by product, format, shift, supplier batch and machine recipe
- Value product, packaging, labour and lost-capacity cost separately
How to make the decision
Work from the required finished result back through the process. Keep compliance, product quality, sustained output and total ownership cost visible together.
- Use first-pass yield to show process capability before rework
- Use defect Pareto to focus corrective work
- Move inspection closer to the defect source where practical
- Verify that apparent improvement is not caused by relaxed inspection
- Link quality loss to process conditions and change history
Common mistakes to avoid
- Reporting only final saleable output
- Combining setup scrap with steady-run defects
- Counting the same reworked unit more than once
- Changing defect categories so trends cannot be compared
Customer decision table
| Measure | Meaning |
|---|---|
| First-pass yield | First-pass good units divided by units entering the process |
| Reject rate | Failed units divided by inspected units |
| Rework rate | Units requiring correction divided by units processed |
| Rolled throughput yield | Combined yield across sequential process steps |
Questions customers also ask
Can a line have high final yield but poor first-pass yield?
Should setup waste be included?
What is the best defect category?
How should automated inspection data be used?
Evidence to retain
Keep the controlled requirement, product and packaging samples, measurements, trial results, supplier scope and acceptance records used for the decision.
Download the planning template
Use the CSV worksheet to allocate evidence, owners, actions and dates before requesting quotations or approving a change.
Related guides and calculators
Need help applying this to your line?
Send the product, pack, current method, measured problem and required result. The more specific the evidence, the more useful the machinery review can be.