Free Scrap Rate & First Pass Yield Calculator

Inputs

Production · single run

Units started / fed in

pcs

Total quantity that entered the process. Scrap (discarded)

pcs

Defective beyond repair, cannot be recovered. Rework

pcs

Defective on the first run but recovered.

Cost per unit (optional)

Material / unit cost per part — unlocks scrap cost.

Multi-stage process (RTY) Rolled throughput yield across multiple steps.

# Input Defects Yield

Six Sigma (DPMO) DPMO & sigma level from defect opportunities.

Defect opportunities per unit Number of possible defect locations per unit (opportunities).

Invalid input

Scrap + rework (50) exceed the quantity started (0). Please correct the values.

Ready to calculate

Enter a quantity started on the left to see first pass yield, scrap rate and final yield.

FPY

Scrap rate

0 ppm

Final yield

incl. recovered rework

Good parts · 1st run

of 0 pcs

Rework rate

0 pcs

FPY vs. final yield: First pass yield counts rework as a defect (first run), while final yield treats reworked parts as good. So FPY ≤ final yield always holds.

Breakdown of the starting quantity 0 pcs total

Good parts 0 · 0 %

Rework 0 · 0 %

Scrap 0 · 0 %

FPY benchmark

80 % 90 % 95 % 100 %

Guidance: ≥ 99 % excellent · 95–99 % good · 90–95 % average · < 90 % needs improvement.

Cost impact

Scrap cost —

0 scrap parts
× — per part

Note: Rework cost (0 parts) is tracked separately and does not equal the full unit cost — it is deliberately not included here.

Multi-stage process Rolled Throughput Yield

—

RTY = the product of all step yields and is therefore always lower than the weakest individual step.

Six Sigma

DPMO — Defects per Million Opportunities

Sigma level — σ Approximation incl. 1.5σ shift

Reference: 6σ ≈ 3.4 DPMO. The sigma value is a common approximation and should be read as guidance, not an exact figure.

Enter the defect opportunities per unit on the left to calculate DPMO and sigma level.

Recommendations

Formulas: FPY = (Started − Scrap − Rework) / Started · RTY = product of step yields. Values are for guidance only. A good companion: the OEE calculator (quality loss Q) and the reason-code logger.

Guide

How to calculate your first pass yield

Five steps from production quantity to first pass yield. All fields can be combined freely — results update live.

1Capture the starting quantityEnter the total number of parts fed into or started in the process — the basis for every rate.

2Enter scrapParts that are defective beyond repair, can no longer be recovered and are discarded.

3Enter reworkParts that were defective on the first run but were recovered through rework.

4Refine optionallyAdd unit cost for scrap cost, “Multi-stage process” for RTY and “Six Sigma” for DPMO & sigma level.

5Read the resultThe FPY ring, scrap rate, final yield and benchmark update automatically — including concrete recommendations.

Formula: FPY = (Starting quantity − Scrap − Rework) / Starting quantity. Example: (1,000 − 30 − 20) / 1,000 = 95 %. Rework deliberately counts as a defect of the first run.

FAQ

Frequently asked questions about first pass yield

Explained briefly: definition, calculation, benchmarks and the difference from RTY, final yield and Six Sigma.

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