Getting more output from the same input.
WHAT YIELD MEASURES
Output as a proportion of input.
WHY IT MATTERS
Material is usually the largest cost, and yield improvement goes straight to profit.
WHERE LOSSES OCCUR
Process waste inherent in the method Setup and startup waste Defects and rework Spillage and handling Trimming and offcuts Theft
WHAT TO MEASURE SEPARATELY
Each of those.
WHY SEPARATELY
They require different responses.
WHAT TO DO ABOUT SETUP WASTE
Reduce changeovers, and refine the startup procedure.
WHAT TO DO ABOUT INHERENT PROCESS WASTE
Establish whether it can be reduced by method or equipment change.
WHAT TO DO ABOUT DEFECTS
Address the cause.
WHAT TO ASK
Whether waste can be recovered or reused.
WHAT EXAMPLES LOOK LIKE
Offcuts reprocessed Off-specification product downgraded and sold By-products sold
WHY THAT MATTERS
It converts a cost into a recovery.
WHAT TO ESTABLISH
Whether downgraded product may be sold, and under what description.
WHY CAREFULLY
Selling substandard product as prime is fraud and it destroys reputation.
WHAT TO RECORD
Waste by category, per run.
WHAT TO SET
A yield target, based on what is achievable.
WHAT TO REVIEW
Runs that fell below it, and why.
WHAT TO TRACK
Yield trend over time.
WHAT A FALLING TREND INDICATES
Material quality, equipment condition, or process drift.
