What is First Time Quality?

First time quality (FTQ), or first time right, is a management strategy that estimates the percentage of usable products at the start of a production run. Essentially, it is used as a metric for evaluating a manufacturer’s production efficiency and how many sellable items there are per sample.

The goal of FTQ is to produce goods that are free of defects on the first try. It is rooted in Six Sigma, a methodology for improving product effectiveness and preventing product losses.

If implemented successfully, FTQ can significantly reduce product waste and repeat work. Learn more about right first time quality in the following sections:

First time quality in manufacturing
Benefits of FTQ
Tips for cultivating first time quality

First time quality in manufacturing

First time quality in manufacturing evaluates process input versus process output. For instance, if a beverage manufacturer produces 1000 bottled drinks per hour but 100 don’t meet quality standards, the measure of first time quality is 90% — with 10% being scrap.

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FTQ consists of five steps, known as define, measure, analyze, improve, and control (DMAIC):

Define what’s wrong with the process.
Measure the defective product impact.
Analyze the cause of the issue.
Improve flawed processes.
Implement quality control.

Learn more about each step in what is first time right and how to improve it.

Benefits of FTQ

FTQ, when used correctly, can decrease product deficiencies and increase customer satisfaction. Some of its benefits include:

Helps identify improvement areas when manufacturers measure first time quality after every process. The number of defects from each production run can illustrate which procedures can benefit from a little tweaking.
Leads to troubleshooting problems faster when the root cause is identified and steps are taken to correct product defects.
Measures procedure efficiency to gauge how many sellable items you produce per sample. Process competence goes hand in hand with worker productivity and how much time and money are put into carrying out a procedure.

Tips for cultivating first time quality

It’s crucial to know where your product flaws are stemming from. Only then can you correct procedures that may be adding to those problems. Check out the following tips to get a better idea of how to improve FTQ in your everyday operations.

Step 1: Inspect materials

The quality of your materials has a huge impact on the goods you produce. It’s important to inspect materials to make sure that you and your suppliers are on the same page when it comes to quality standards.

A supplier may sometimes distribute supplies that have defects from the get-go. Failure to remove defective materials can lead to faulty products down the line.

Step 2: Practice machine and equipment upkeep

Once you’ve ruled out that your materials are not the issue, it’s vital to review your machinery for potential malfunctions. Over time, even the most advanced equipment can break down.

Regular machine inspection and repair is necessary to ensure that your equipment is not the reason for product defects. Routine maintenance can also prevent workers from having to stop a production process because they are waiting for equipment to be fixed. If the issue is resolved before a worker begins a process, it reduces the chances of having to stop operations.

Step 3: Implement process documentation

Proper documentation of procedures and the steps involved in carrying out each one can decrease the chances of imperfect goods. This is imperative for first time quality, especially if there’s changeover in a company. The better your written procedures are, the more likely that workers will perform tasks right the first time around.

Up-to-date instructions ensure that everyone knows how to execute duties in the right order and in the right way, enabling them to produce the same outcome each time. This can help eliminate any defects from human error.

Augmentir offers solutions to increase first time quality for all your frontline operations. Our connected worker solution will help you digitize and transform how you write and implement production procedures to eliminate inconsistencies. Learn more about our quality use cases.

Interested in learning how Augmentir’s connected worker solution can help you reduce defects and improve quality within your manufacturing operation? Get in touch with us for a free demo.