ISO9001 Approved Manufacturer of shaft manufacturers
A formula is an expression method that people find when they study things in nature and express them in a certain way. It is an equal or unequal connection between the quantities of different things in nature, it accurately reflects the internal and external relationship of things, and it is the basis for us to reach from one thing to another, so that we can better understand The essence and connotation of things. ISO9001 Approved Manufacturer of shaft manufacturers
01 Scrap rate
Definition: This percentage is obtained by dividing the scrap material cost by the total production cost or by dividing the total scrap quantity by the total production quantity of the product.
Purpose: To be used as an outcome measure to determine whether the process is producing and assembling parts according to specification.
Formula: Scrap rate % = (material amount of scrap / total production cost) × 100% or (total scrap quantity / total production quantity of products) × 100%.
the term:
Scrap material amount: is the value of the materials used in the scrap.
Total production cost: is the sum of labor, materials, and factory burdens (water, electricity, etc.). ISO9001 Approved Manufacturer of shaft manufacturers
Application/Information: Scrap calculations are obtained directly from the unit’s financial system. If the company’s financial system cannot separate the value of scrap materials from labor and burden costs, it should coordinate with relevant departments as soon as possible.
02Rework rate
Definition: The proportion of time spent in rework activities, obtained by dividing rework hours by production labor hours or the total number of reworked (reworked) items divided by the total production volume.
Purpose: To be used as an outcome measure to highlight those operating stations that need improvement in first-pass quality.
Formula: Rework rate % = (rework hours/total production labor hours) x 100% or (total number of reworked (reworked) products/total production number) x 100%.
the term:
Rework Hours: Refers to the time spent reprocessing, sorting, and repairing workpieces that will become scrap. These hours can be spent on work in process, finished products, and purchased parts or materials. Rework time includes things like repair, repackaging, resorting, additional inspection activities and containment. Rework time includes internal or external activities. Should include direct time plus the direct time portion of overtime. ISO9001 Approved Manufacturer of shaft manufacturers
Productive Labor Hours: The total working hours of direct/productive labor workers (including direct time plus the direct part of overtime hours).
Application/Information:
Occasional inspections of direct labor workers should not be considered rework. Any product that is re-entered into the production process shall be considered rework. A portion of the total labor content of a production line should be considered rework. This part will be determined based on the condition of the reworked product. For example, at the final inspection, 10% of the products in a painting line were rejected, and the painting line had a total of 20 operators, and the reworked products (10%) needed to be painted again, 10% of the total working time of the painting line Considered to be used for rework. 10% × 20 people × 8 hours = 16 rework hours.
03Product warehousing inspection pass rate
Definition: It is obtained by dividing the qualified quantity of product in-stock inspection by the total quantity of in-stock inspection.
Purpose: Used as a process metric to measure the quality level of the entire production process.
Formula: Product warehousing inspection pass rate % = (product warehousing inspection qualified quantity / warehousing inspection total quantity) × 100%. ISO9001 Approved Manufacturer of shaft manufacturers
04 The number of defective products per million
Definition: The number of customer returns/rejections or nonconforming products per million units as a percentage of the total number of shipments or total production.
Purpose: To be used as an outcome measure to fully demonstrate the impact of product dissatisfaction, allowing focus on problem solving.
Formula: Customer Return Rate = Number of Returned Pieces / Number of Shipped Pieces Total Product Quantity * 1,000,000 or Product Defect Rate = Total Unqualified Product / Total Product Quantity * 1,000,000.
05Quality accident
Definition: The number of production stoppages per year due to non-conforming products. Cause the company to stop shipping, stop production, or require that manufactured products be corrected.
Purpose: To be used as an overall outcome measure to reflect product dissatisfaction caused by the number of company quality incidents, in order to focus on problem solving.
Formula: Quality Incidents = Number of plant production stoppages per year due to company-defined quality incidents. ISO9001 Approved Manufacturer of shaft manufacturers
06 Parts processing defect rate
Definition: The inspection pass rate or the process pass rate is the result of dividing the qualified quantity of parts in one production process by the total quantity of parts produced or the weighted average;
Purpose: Used as a process metric to determine the quality level of the production process.
Formula: (inspection pass rate or process pass rate) % = (one-time qualified number of processes / total number of parts produced) × 100% Parts processing failure rate = (parts failed number / parts production input number) × 1,000,000.
07One-time pass rate of customer inspection
Definition: Refers to the delivered product, the quantity received after passing the customer inspection at one time divided by the total quantity of delivered product.
Purpose: To be used as an outcome measure to measure the quality level of outbound finished goods.
Formula: one-time pass rate of customer inspection % = (quantity received after one pass customer inspection/total quantity of delivered products) × 100%.
08Incoming inspection pass rate
Definition: within a certain period of time, the number of qualified incoming materials divided by the number of incoming inspections.
Purpose: To be used as an outcome measure to monitor the quality level of the supplier’s supply.
Formula: incoming inspection pass rate% = ( incoming incoming inspection qualified quantity / incoming incoming inspection total quantity) × 100%. ISO9001 Approved Manufacturer of shaft manufacturers
09 Quality cost
Definition: Simply defined as the cost of failure (loss) over a certain period of time.
Purpose: To be used as a result measure to reflect the comprehensive results of the operational effectiveness of the company’s quality management system.
Formula: quality cost = internal failure (loss) cost + external failure (loss) cost; internal failure (loss) cost = scrap loss cost + rework or repair loss cost; external failure (loss) cost = customer return loss cost + product liability fee + complaint fee; ratio of quality cost to sales = (quality cost ÷ sales) × 100%.
the term:
Internal failure (loss) cost: the loss caused by the failure of the product to meet the quality requirements before delivery;
External failure (loss) cost: the loss caused by the failure of the product to meet the quality requirements after delivery;
Scrap loss fee: the cost of scrapping due to finished products, semi-finished products, and work-in-process that do not meet the quality requirements and cannot be repaired or are not economically worth repairing;
Rework or repair loss fee: The fee paid for repairing non-conforming products to meet the quality requirements or expected use requirements;
Customer return loss fee: the waste loss cost of customer return;
Product liability fee: related compensation for loss caused by product quality failure;
Complaint fee: The cost of repairing or replacing a product that customers complain about has a quality problem. ISO9001 Approved Manufacturer of shaft manufacturers
10 batch failure rate
Definition: refers to the ratio of the number of batches that need to be reworked (or repaired or scrapped) to the total number of inspection batches in all inspection batches within a certain period of time if the inspection is judged to be unqualified.
Purpose: To be used as an outcome measure to monitor the overall quality level of the process.
Formula: batch failure rate = number of failed batches / total number of inspection batches * 100%.
the term:
Inspection batch: It is a batch of products submitted for inspection, and is also a batch of products collected as inspection objects. Usually, the inspection batch should consist of unit products of the same model, grade and type (size, characteristics, composition, etc.), and with basically the same production conditions and production time.
Production batch: refers to a certain number of batches of products that are put into production as determined by the production plan. ISO9001 Approved Manufacturer of shaft manufacturers
