Template

First Pass Yield (FPY) Tracking & Coaching Sheet

An interactive FPY tracking and coaching sheet that captures FPY by operation, defect breakdowns, immediate containment, coach conversation notes, improvement actions, and verification so teams can make defects visible, assign ownership, and follow through.

Interactive Tool

FPY Tracking & Coaching Sheet

Purpose: Capture first-pass yield at the operation level, surface frequent defect types, record immediate containment, and guide a short coach/operator conversation that results in owned improvement actions and verifications.

How to use: Fill this form at the end of the run, shift, or problem observation. Enter counts, select common defect types, describe containment and probable cause, agree short-term and longer-term actions, and schedule verification. The FPY percentage formula is: FPY (%) = (Good pieces (First Pass) / Planned / Started pieces) × 100. Use the verification fields to close the loop and prevent recurrence.

YYYY-MM-DD
Identify the operation or machine (e.g., Op 3 - Drill Press)
Total parts started into this operation during the period
Parts that completed this operation without requiring rework
Number of parts reworked to meet spec (if known)
Enter FPY percent. Formula: FPY = (Good pieces (First Pass) / Planned / Started pieces) × 100
Select the defect types that occurred most frequently during the observation or run.
If 'Other' selected, describe the defect
Count for 'Other' defects
What was done to stop bad parts from moving downstream? (quarantine, stop line, rework at source, visual flagging, etc.)
Record simple evidence: when it started, what changed, and why you suspect this cause.
Quick steps to stabilize the process (who will do what, by when)
Examples: update standard work, replace tooling, schedule training, engineering fix
Does the operator agree and understand the action and verification requirements?
Date when coach will verify the action (YYYY-MM-DD)
Mark when coach verifies the effectiveness of the action
What did verification find? Is further action needed?
Was work instruction, checklist, or job aid updated to prevent recurrence?
Was training scheduled for operators or maintenance?
Anything else the coach or operator wants to record
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