Use ERP quality data to cut defects, prevent rework and pass audits fast.
First-pass yield (FPY) measures how many parts leave a process good the first time. It reveals the true cost of defects without hiding rework.
The formula is simple, but the value comes from accurate data captured in the flow of work. To make FPY meaningful, you need traceability by work order, operation, lot or serial so defects point to the exact step that needs attention. ERP does this by tying labor, scrap, inspections and materials to each operation on the routing.
When operators record scrap as it happens and QA logs nonconformances to the job, you see where defects start and what they cost. Start by mapping your top defect types to a short list of defect codes that operators can remember. Add clear examples in work instructions and train on how to pick the right code. Equip each station with scanners and labels so serial or lot tracking is quick and accurate. Keep screens simple so data entry does not slow the line.
With clean traceability, FPY by operation and by part family will show which steps need standard work, tooling refresh, or a process change. For definitions and plain-language quality concepts, see ASQ on QMS. Next, make the data visible. Use dashboards that show FPY for the last 24 hours and the last week for the cells that matter most. Link each defect code to an owner and a simple containment checklist so the line knows what to do when numbers slide.
When the story is visible and the response is clear, FPY becomes a daily habit, not a quarterly report.
Preventing rework starts with in-process checks that catch mistakes before they flow downstream. Attach checklists, photos, torque specs and go/no-go criteria to each operation. Require a quick sign-off and log who did it and when. If a measurement falls out of range, trigger a nonconformance on the spot with a photo and a short note. Tie these checks to part revision and effective date so the right instruction shows every time.
ERP makes this practical by embedding documents in routings and controlling revisions so only the latest instruction is visible. Alerts keep teams ahead of trouble. If FPY drops below a threshold, send a message to the cell lead and quality. If the same defect repeats three times, launch a corrective action template with root cause fields ready to go. Review trends weekly for the 10 parts that drive most defects. Compare shifts to spot training needs and compare suppliers when purchased components drive escapes. For software designed for this flow, explore Quality Control and how ERP supports ISO programs in ERP and ISO 9001.
When checks live in the same system as jobs, materials and people, you prevent defects rather than just counting them. That is how FPY improves without slowing production.
Audits should confirm good work, not derail it. Digital records turn audit prep into a search instead of a scramble. Pull up a work order and you should see the revision of the instruction used, who ran each operation, inspection results, any nonconformances and the disposition. If the part is serialized or lot controlled, you should see where each unit flowed. This level of traceability speeds ISO or customer audits and builds trust with your buyers.
Set up a simple review cadence. Daily checks at the cell to confirm documents are current and sign-offs complete. Weekly checks by quality to verify a sample of jobs have full traceability. Monthly management review to look at FPY trends, cost of poor quality and status of corrective actions. If you are building the foundation for clean data capture, consider going paperless where it hurts most using the ERP Paperless application so sign-offs and photos live with the job.
Improving FPY is not about perfection. It is about fast feedback, simple standards and steady coaching. When ERP holds the playbook and the proof, your customers see fewer defects, your team spends less time fixing and your margins improve.