CAN A PROCESS WITH 100%
ROLLED
THROUGHPUT
YIELD
BE CONSIDERED INEFFICIENT?
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MEANING
Rolled Throughput Yield (RTY) is the
probability of producing a defect-
free product when it has to go
through multiple process steps. It is
the overall process yield in a multi-
step process or an operation with
various functions. It is the product
of yields at each process step of
the entire process / operation.
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Based on the calculated Rolled
Throughput Yield of 100%, the
process cannot be inefficient. But
this calculation could make
assumptions, which may reveal
the inefficiencies in the process.
These assumptions may result in
some convenient omissions,
boosting the Rolled Throughput
Yield to 100%.
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ASSUMPTIONS:
1. Related to available time: The
equipment or plant is known for
operation 24 X 7 = 168 hours a week,
but the Management chooses, or
there is business only for running five
days a week for two shifts of eight
hours each. Within 80 hours per
week, the plant operates at 100%
rolled Throughput Yield, but from an
overall time availability angle, there is
already a loss of around 52% ([168 –
80] / 168).
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2. Related to Capacity: A batch
process could operate in a drum
with a design capacity of 80
metric tonnes. Due to poor
maintenance, some residue of the
charge has solidified inside the
drum reducing its usable capacity
to 70 metric tonnes. The Rolled
Throughput Yield on 70 metric
tonnes is indeed 100%, but w.r.t.
the Design Capacity, the yield loss
is 10/80 = 12.5%.
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3. Related to Scope: For most
product types, the Rolled
Throughput Yield is 100%, but for
some product types, the yield
drops in one or more processes.
But these product types are
scoped out when calculating or
presenting Rolled Throughput
Yield calculations.
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4. Related to Mode of Operation:
Some low-yield processes get
outsourced so that the
“organization’s” Rolled Throughput
Yield remains 100%. But if Rolled
Throughput Yield is assessed for
the End-to-end process, it may
go below 100%.
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5. Related to Changeovers:
Changeovers are “Non-
production” times. So, these times
are not included in the available
time. If considered correctly, the
Rolled Throughput Yield will be
less than 100%.
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