Key takeaways
Short answer: Overall yield counts good output regardless of how many times parts went through rework. Rolled throughput yield (RTY) is the probability a part makes it through every step right-first-time. RTY exposes the hidden cost of rework that overall yield masks. See also Rolled Throughput Yield vs First-Pass Yield.
A 4-step process. Each step has 95% right-first-time. Reworked parts pass.
The 18.5% gap is rework. Cost: labor, time, scrap risk.
Overall yield rewards rework. RTY exposes it. Plants that optimize for RTY reduce hidden cost; plants that optimize only for overall yield never see the issue.
Result is RTY. Express as percentage or DPMO.
1. Reporting only overall yield. Rework cost invisible.
2. Counting reworked parts as first-pass. RTY corrupted.
3. Not measuring per-step rates. Cannot calculate RTY.
4. Treating RTY < 90% as acceptable. World-class is 99%+.
OEE Quality reflects good parts out. RTY drills into how many got there right-first-time. Plants pursuing six sigma focus on RTY; plants pursuing OEE alone may miss it.
Fabrico's OEE module tracks first-pass and rework counts per step, calculates RTY automatically, and surfaces the worst step.
See how Fabrico captures this automatically — explore OEE for manufacturing or book a demo.
First-pass yield is per step. RTY is the product across all steps.
99%+ for high-volume processes.
Yes. Overall yield for customer; RTY for internal improvement.
RTY extends to networks; multiply branch probabilities.
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