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Topic Calculate Expected DPPM of Assembly From Known DPPM of Parts

Calculate Expected DPPM of Assembly From Known DPPM of Parts

July 11, 2012Comments Off

Home › Forums › Operations › Manufacturing › Calculate Expected DPPM of Assembly From Known DPPM of Parts

This topic has 2 voices, contains 3 replies, and was last updated by Avatar of Chris Seider Chris Seider 55 days ago.

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July 11, 2012 at 9:57 am #183821

Thomas V.

Hello!

I got a task from our CEO to assure DPPM rate of new product under certain value – for example 1,500.
As a project manager – originating from R&D – I can see that this will be mission impossible. The reason is in our suppliers that are really … well … crappy.
Immediately after I got a task I figured out that for a new product which consists of 48 parts – and each with expected DPPM of 2,000 to 3,000 – target is simply impossible.

Can any of you gentleman/ladies here help me with a formula (for our CEO) with which I will present to him what should be the average DPPM for 48 parts to achieve 1,500 DPPM with new product?

Thank you 1000 times!

Best regards
Thomas V.
July 16, 2012 at 5:36 am #183923
Avatar of Bartosz Jankowski
Bartosz Jankowski
Reputation - 0
Rank - Aluminum

First of all, I would use normalized yield as your target. That is, 1000000-1500=998500 ppm efficiency.
Secondly, change into 0,998500, than a root = (0,998500)^(1/48), which gives an average yield for each part = 0,999968727.
Lastly, to calculate defect rate: (1-0,999968)*1000000=3,4 ppm defect rate for each part.
Interesting target for each part. A coincidence?

Best Regards,
March 31, 2013 at 9:56 pm #192359
Avatar of Andy
Andyxia
Reputation - 19
Rank - Aluminum

To my understanding, average DPPM does not make sense. You can check the statistics theory, you never know it is better or not from average. I suggest that you can sort parts by group, and then you’ll get the DPPM for each group.Comparing all groups and similar group should have similar DPPM.That is your first target to reach.Finally, according to your experience which could be improved by what actions and then you can plan to do it.
I think your boss would like to hear this roadmap.Just step by step.
April 1, 2013 at 6:20 am #192387
Avatar of Chris Seider
Chris Seider
Reputation - 3020
Rank - Titanium

Maybe you were challenged to do analysis of where your defects are coming from and to find new sourcing or work with those suppliers to improve their quality levels and I don’t mean improving quality levels with more inspection!
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