First Pass Yield (FPY) Improvement Experiment Pack

{"Title":"FPY Improvement Experiment Pack (Pilotable)","IntroductionHtml":"

Welcome

This pack helps teams run focused experiments to raise first-pass yield (FPY) by catching defects earlier, simplifying steps, and testing error-proofing ideas. Use the guided experiments to scope a small pilot, capture observations, and evaluate impact using a simple scorecard — so you learn quickly and avoid treating inspection as the primary quality strategy.

How to use this playbook: Select one or two experiments, define a pilot scope (units, stations, days), run the changes, record results here, then review the pilot evaluation to decide next steps. Aim for measurable improvement (FPY, rework hours, throughput) and clear learnings for scaling.

Note: This tool records pilot data so you can compare before/after and build organizational memory.

","SubmitLabel":"Save Pilot Results","SuccessMessage":"Pilot saved. Use this entry to compare experiments and plan next tests.","DataType":"fpy.experiment.pack.v1","SchemaVersion":1,"Fields":[{"Key":"experiments_selected","Type":"checkbox","Label":"Experiments to run (pick the ones you will test)","HelpText":"Choose the experiments you'll run during this pilot. Run 1-2 at a time for clear learning.","Options":[{"Value":"add_in_process_inspection","Label":"Add in-process inspection at a targeted operation"},{"Value":"error_proofing_poka_yoke","Label":"Install a poka-yoke / physical error-proofing"},{"Value":"standard_work_and_visuals","Label":"Introduce or tighten standard work and visual cues"},{"Value":"process_simplification","Label":"Remove or simplify steps that cause variability"},{"Value":"tooling_fix_or_maintenance","Label":"Fix or improve tooling/jigs"},{"Value":"operator_coaching","Label":"Targeted operator coaching and quick skills refresh"},{"Value":"supplier_quality_check","Label":"Tighten incoming material gating/inspection"}]},{"Key":"pilot_scope_units","Type":"number","Label":"Pilot scope — planned number of units to include","HelpText":"How many units will you include in this pilot? Choose a size that gives meaningful measurement but remains manageable."},{"Key":"pilot_duration_days","Type":"number","Label":"Pilot duration — planned days","HelpText":"How many days will you run the pilot?"},{"Key":"root_cause_checklist","Type":"checkbox","Label":"Root-cause checklist — likely defect families to investigate","HelpText":"Check all that apply for this defect family. Use these as prompts during root-cause analysis.","Options":[{"Value":"material_variation","Label":"Material or component variation"},{"Value":"tooling_wear_or_setup","Label":"Tooling, fixture, or setup issues"},{"Value":"operator_error_or_training","Label":"Operator technique or training gap"},{"Value":"process_drift_or_parameter","Label":"Process parameter drift or unstable process"},{"Value":"measurement_or_calibration","Label":"Measurement, gage, or calibration errors"},{"Value":"design_or_tolerancing","Label":"Design tolerance or assembly fit"},{"Value":"environmental_conditions","Label":"Environmental causes (temp, humidity, contamination)"},{"Value":"supplier_issue","Label":"Supplier variability"},{"Value":"work_instructions_missing","Label":"Missing, unclear, or outdated work instructions"}]},{"Key":"inspection_points","Type":"checkbox","Label":"In-process inspection points to add or strengthen","HelpText":"Pick points to sample or inspect during the pilot.","Options":[{"Value":"incoming_material_gate","Label":"Incoming material gate check"},{"Value":"setup_verification","Label":"Setup verification / first-piece check"},{"Value":"during_operation_checkpoint","Label":"Checkpoint during a critical operation"},{"Value":"assembly_hold_point","Label":"Assembly hold-point inspection"},{"Value":"final_quality_check","Label":"Final quality check before handoff"},{"Value":"tooling_condition_check","Label":"Tooling condition / cleanliness check"},{"Value":"measurement_check","Label":"Gage/measurement validation during shift"}]},{"Key":"poka_yoke_idea","Type":"textarea","Label":"Poka-yoke or error-proofing idea (describe succinctly)","HelpText":"Describe the physical or process change to prevent the defect (fixtures, guides, sensors, templates, simple alarms)."},{"Key":"poka_yoke_feasibility","Type":"select","Label":"Feasibility of the idea","HelpText":"Estimate feasibility for the pilot and short-term deployment.","Options":[{"Value":"low","Label":"Low (requires significant design or capital)"},{"Value":"medium","Label":"Medium (simple fixture or tooling change)"},{"Value":"high","Label":"High (quick, low-cost change)"}]},{"Key":"digital_inspection_template_items","Type":"checkbox","Label":"Digital inspection template — common checklist items to include","HelpText":"Select items to include in your digital inspection form for the pilot.","Options":[{"Value":"part_dimensions","Label":"Critical part dimensions measured"},{"Value":"visual_defect_check","Label":"Visual defect check (scratches, cracks, contamination)"},{"Value":"torque_or_tightness","Label":"Torque/fastener checks"},{"Value":"leak_or_seal_test","Label":"Leak/seal/functional test"},{"Value":"label_or_serial_check","Label":"Label, serial, or traceability data"}]},{"Key":"digital_inspection_sample_size","Type":"number","Label":"Sample size or frequency (e.g., every Nth unit)","HelpText":"Enter the numeric sample size or frequency for inspections. Use 1 for every unit."},{"Key":"digital_inspection_frequency","Type":"select","Label":"Inspection frequency","HelpText":"How often will this inspection run during the pilot?","Options":[{"Value":"every_unit","Label":"Every unit"},{"Value":"every_10th","Label":"Every 10th unit"},{"Value":"per_shift_random","Label":"Random samples per shift"},{"Value":"per_batch","Label":"Per batch"}]},{"Key":"baseline_fpy_percent","Type":"number","Label":"Baseline FPY (%) before pilot","HelpText":"Enter the measured FPY percent for the area/process before the pilot."},{"Key":"pilot_fpy_percent","Type":"number","Label":"FPY (%) observed during/after pilot","HelpText":"Enter the FPY percent observed during or immediately after the pilot."},{"Key":"scorecard_fpy_change","Type":"scale","Label":"FPY impact — direction and magnitude","HelpText":"Rate the magnitude of FPY improvement from this pilot (0 = no change, 10 = major improvement).","Min":0,"Max":10},{"Key":"scorecard_rework_hours_saved","Type":"number","Label":"Estimated rework hours saved per shift (numeric)","HelpText":"Estimate the reduction in rework hours per shift or per pilot unit set."},{"Key":"scorecard_throughput_change","Type":"scale","Label":"Throughput impact","HelpText":"Rate net throughput impact (positive values = throughput improved).","Min":0,"Max":10},{"Key":"scorecard_operator_burden","Type":"scale","Label":"Operator burden or extra work required","HelpText":"Rate added operator burden (0 = heavy extra work, 10 = no additional burden). Higher is better.","Min":0,"Max":10},{"Key":"lessons_learned","Type":"textarea","Label":"Key observations and lessons learned","HelpText":"What did you learn about root causes, data quality, or unintended effects?"},{"Key":"recommended_next_steps","Type":"textarea","Label":"Recommended next steps","HelpText":"E.g., scale, adjust, design robust poka-yoke, integrate with MES, or stop and choose a different experiment."}]}