NPI, DFM/DFA & Engineering Change worked example

Pilot Yield at 68% target first-pass pilot yield: a worked example

This worked example runs the pilot yield numbers for a tougher week than the baseline: 68% target first-pass pilot yield instead of the typical 95%. Estimate pilot yield for npi, dfm/dfa and engineering change using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.

The inputs for this scenario

  • Good units off the pilot build: 8 count (held at the documented default)
  • Total units started in the pilot run: 250 count (held at the documented default)
  • Target first-pass pilot yield: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Pilot yield rate = pilot yield count ÷ total pilot yield population × 100.
  • Pilot yield rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Pilot yield gap to target works out to 64.8 points at these inputs.
  • Pilot yield count works out to 8 count at these inputs.
  • Total pilot yield population works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target first-pass pilot yield sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • Use it after each pilot or pre-production build to decide whether a product is ready to move to volume ramp or needs another build loop. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Pilot yield rate: 3.2 % (headline result)
  • Pilot yield gap to target: 64.8 points
  • Pilot yield count: 8 count
  • Total pilot yield population: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Pilot Yield calculator, set target first-pass pilot yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.