First-Time-Right and DHU reduction

Learning objectives

• Define FTR and DHU with matching numerators and denominators.
• Locate the vital few defect drivers by operation, hour and material.
• Design quality-at-source controls that reduce defects without slowing output.

Problem and CTQ

FTR = first-pass accepted / first-pass inspected × 100%. DHU = defects / units inspected × 100. Align inspector agreement before publishing either number.

DMAIC path

• Attribute agreement and inspector calibration.
• Pareto by operation, defect type, hour, operator, machine and material.
• Analyse exposure and time sequence; confirm cause at gemba.

Improvement choices

• Quality-at-source, first-piece approval and standardized method/settings.
• Defect references, needle/thread controls and targeted poka-yoke.
• Feedback loops from downstream inspection back to source operation.

Control plan

• FTR/FPY, DHU, repair minutes, repeat defect, audit agreement, output and cost of poor quality.
• Owner per top defect with a weekly repeat-defect review.

Garment-factory example

A denim line records 14.2 DHU driven by two defects: skip-stitch on waistband and needle marks on back-yoke. Needle-change frequency and a pressure setting standard cut DHU to 6.8 in six weeks without output loss.

Common mistakes

• Confusing defects with defective garments.
• Gaming FTR by pre-inspecting and repairing before the checkpoint.