CPAI Editorial
Research, field notes, and practical guidance from the CPAI community.
7 articles
The same rework keeps coming back, even after the last fix. Matthew Wright on what to check on the shop floor before adding another control or more automation.
by Matthew Wright
A finished batch can hide what it took to make it. Geoff Ellis, COO of Wherefour, on what rework really costs a food and beverage plant.
by Geoff Ellis
Indirect labor in manufacturing is the cost of work that supports production but cannot be traced economically to one product or job. Common examples include production supervision, quality support, maintenance, sanitation, materials handling, and production planning. The cost may enter manufacturing overhead, but the hours should still be attached to the loss event, batch, or […]
by CPAI Editorial Team
The true cost of rework is the incremental cost of making a nonconforming unit acceptable again, not simply the material in the hold area. Start with added material, rework labour, QA or retest, processing and machine time, and the cleaning, maintenance, or documentation work the event creates. Add capacity opportunity cost when the rework displaces […]
by CPAI Editorial Team
Yield loss in manufacturing is the gap between a declared comparison basis and the good output a process actually produces. The number is only useful when the basis is clear. A report can show performance close to standard while actual yield remains far below a current theoretical or validated basis, especially when the standard already […]
by CPAI Editorial Team
First-pass yield (FPY) is the percentage of units that meet requirements without a later rework pass. The basic formula is first-pass-good units divided by the units entering the batch, multiplied by 100. Final or blended yield can be higher because it may include units accepted after rework. Rolled throughput yield (RTY) answers a different question: […]
by CPAI Editorial Team
The hidden factory is the unofficial work and capacity consumed by defects, rework, workarounds, queues, and other non-value-adding activity that ordinary reports do not join.
by CPAI Editorial Team
