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In the daily work of textiles, I believe that many quality indicators are often used. However, if you study the specific definitions of these indicators, many people are confused or unable to organize words to express them. Whether you are a veteran who has been in the textile industry for many years or a novice who has just entered the textile industry, you can definitely collect the next "dry goods"!
1. Scrap rate
Definition: Scrap rate refers to the proportion of scrap materials in the total production cost, or the proportion of the total number of scraps to the total number of products produced.
Purpose: Scrap rate can be used as an outcome measure to determine whether the process is producing and assembling parts according to specification.
Formula: scrap rate = (material cost of scrap / total production cost) × 100%
or = (total scrap/total production) x 100%
noun term:
① Waste material cost: It is the value of the material used in the waste.
② Total production cost: It is the sum of labor, material and factory burden (water, electricity, etc.).
Note: The data source for calculating the scrap rate is the direct company's financial system. If the company's financial system cannot separate the value of scrap materials from labor and burden costs, it should coordinate with relevant departments as soon as possible.
2. Rework rate
Definition: Time spent on rework of non-conforming product as a percentage of total man-hours, or rework/rework defective as a percentage of total production quantity.
Purpose: Rework rate can be used as an outcome measure to highlight those operating stations that need improvement in first-time quality.
Formula: Rework rate = (rework hours/total production labor hours) × 100%
or = (total quantity of reworked (reworked) items/total production quantity) x 100%
noun term:
① Rework man-hours: Refers to the time spent on reprocessing, sorting, and repairing workpieces that will become scrap. This time can be spent on work in process, finished products, and purchased parts or materials. Rework time includes things such as repairs, repackaging, resorting, additional inspection activities and containment. Rework time includes internal or external activities and shall include direct time plus the direct time portion of overtime.
② Total productive labor hours: the total working hours of direct/productive labor workers (including direct time plus the direct part of overtime hours).
Note: Occasional inspections of direct labor workers should not be considered rework. Any product that is re-entered into the production process shall be considered rework, and this portion will be determined based on the reworked product.
3. Product warehousing inspection pass rate
Definition: The ratio of the qualified quantity of the product in the warehouse inspection to the total quantity of the inbound inspection.
Purpose: The pass rate of product warehousing inspection can be used as a process metric to measure the quality level of the entire production process.
Formula: product warehousing inspection pass rate = (product warehousing inspection qualified quantity / warehousing inspection total quantity) × 100%
4. The number of defective products per million
Definition: The number of unqualified products per million is the customer return rate and the product defect rate. Refers to the ratio of the number of customer returns/rejections or the number of non-conforming products per million units to the total number of shipments or total production.
Purpose: This percentage can be used as an outcome measure to fully demonstrate the impact of product dissatisfaction, which helps manufacturers focus on problem solving.
Formula: Customer Return Rate = Number of Returned Pieces / Number of Shipped Pieces Total Product Quantity * 1,000,000 or Product Defect Rate = Total Unqualified Product / Total Product Quantity * 1,000,000.
5. Quality accident
Definition: Quality incidents refer to the number of production stoppages per year due to substandard products. A quality incident can cause a company to stop shipping, stop production, or require that a manufactured product be corrected.
Purpose: Quality incidents can be used as an overall outcome measure to reflect product dissatisfaction caused by the number of company quality incidents. This indicator helps companies focus on solving problems.
Formula: Quality incidents = number of plant production stoppages per year due to company-defined quality incidents
6. Inspection pass rate or process pass rate
Definition: Inspection pass rate or process pass rate is the ratio of the one-time qualified quantity of the product production process to the total product production quantity.
Purpose: The inspection pass rate or the process pass rate can be used as a process metric to determine the quality level of the production process.
Formula: inspection pass rate or process pass rate = (one-time qualified number of process / total number of products produced) × 100%
7. One-time pass rate of customer inspection
Definition: The one-time pass rate of customer inspection refers to the proportion of the delivered products, and the quantity received after passing the customer's inspection at one time accounts for the proportion of all delivered products.
Purpose: To be used as an outcome measure to measure the quality level of outbound finished goods.
Formula: One-time pass rate of customer inspection % = (quantity received after one pass customer inspection/total quantity of delivered products) × 100%
8. Qualified rate of incoming inspection
Definition: The incoming inspection pass rate is also called the incoming one-time inspection pass rate. It refers to the proportion of the number of qualified incoming inspections to the total incoming inspections within a certain period of time.
Purpose: To be used as an outcome measure to monitor the quality level of the supplier's supply.
Formula: incoming inspection pass rate % = (incoming incoming inspection qualified quantity / incoming inspection total quantity) × 100%
9. Quality cost
Definition: The cost of quality is the cost of failure or loss over a certain period of time.
Purpose: The cost of quality can be used as an outcome measure to reflect the comprehensive outcome of the operational effectiveness of the company's quality management system.
formula:
① Quality cost = internal failure (loss) cost + external failure (loss) cost
② Internal failure (loss) cost = scrap loss fee + rework or repair loss fee
③ External failure (loss) cost = customer return loss fee + product liability fee + complaint fee
④ Ratio of quality cost to sales = (quality cost ÷ sales) × 100%
noun term:
① Internal failure (loss) cost: the loss caused by the failure of the product to meet the quality requirements before delivery;
② External failure (loss) cost: the loss caused by the failure of the product to meet the quality requirements after delivery;
③ Scrap loss fee: the cost of scrapping due to finished products, semi-finished products, and in-process products that do not meet the quality requirements and cannot be repaired or are not economically worth repairing;
④ Rework or repair loss fee: the fee paid for repairing substandard products to meet the quality requirements or expected use requirements;
⑤ Customer return loss fee: loss of waste products returned by customers;
Product liability fee: related compensation for loss caused by product quality failure;
⑥ Complaint fee: Expenses for repairing or replacing products with quality problems that customers complain about.
10. Batch failure rate
Definition: Batch failure rate refers to the ratio of the number of batches that need to be reworked (or repaired or scrapped) to the total number of inspection batches in all inspection batches within a certain period of time if the entire inspection batch needs to be reworked (or repaired or scrapped) due to unqualified inspections. .
Purpose: The batch rejection rate can be used as an outcome measure to monitor the overall quality level of the process.
Formula: batch failure rate = (unqualified batches / total inspection batches) * 100%
noun term:
① Inspection batch: It is a batch of products submitted for inspection, and is also a batch of products collected as inspection objects. Usually, the inspection batch should consist of unit products of the same model, grade and type (size, characteristics, composition, etc.), and with basically the same production conditions and production time.
② Production batch: refers to a certain number of batches of products that are put into production as determined by the production plan.
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