DPMO Calculation, Formula, Template & Manufacturing Example
DPMO Calculation, Formula, Manufacturing Example & DPMO Excel Template
Hello readers! Today we will be discussing on DPMO calculation with manufacturing examples. The full form of DPMO is defects per million opportunities. Similarly, dpmo there are 3 more popular terms used in quality for the calculation of defect level and these are [1] DPPM, [2] DPO, [3] DPU. These terms are also frequently used in six sigma project work. If you would like to download the sample template of all 4 calculations in a single sheet then download it from below given link.
DPMO Calculation Excel Template–DOWNLOAD
Formula of DPMO, DPPM, DPO, DPU:
DPU (Defects per unit):
DPU Formula = Total number of Defects / Total units
DPO (Defects Per Opportunity):
DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)
DPMO (Defects per million opportunities):
DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000
DPPM (Defective Parts Per Million):
DPPM Formula = (Total Defective parts / Total parts) x 1000000
First of all, below example-1 is one of the scenarios that are given for calculating the DPMO, DPPM, DPO, and DPU for all my article readers. So, this is the task for you my readers for your better understanding. Similarly, we are also going to solve one of the scenario-based questions for calculating the DPMO, DPPM, DPU, and DPO.
Example-1 (Task for the reader):
Suppose a sheet metal automobile manufacturing company, produces an automobile part. In the press shop, we found that 4 parts had been rejected at press machine-1 & 9 parts at press machine-2. When a QA engineer had analyzed, he found that the total defective product has 16 defects. And defects opportunity per parts is 5 and total 1100 parts had been produced. Calculate the DPMO, DPPM, DPU and DPO?
Have you completed the calculation of above example-1 or not? If not yet then, we are going to help to calculate the same. First of all, note down the data, i.e. Total defects, Total defective parts, defects opportunity per part, total parts produced and total defects opportunity. I know that it will take more time for manual calculation of all calculations, that is why we are recommending you to download our excel automatic calculation template for easy and time-saving calculation. Downloading link is given at top of the articles just try to download the format or template. I would request you all my readers, you just calculate the DPMO and DPPM manually and try to match your value with Excel calculation, which is given below;
I hope you have completed the matching of the value calculated by the automatic excel template and your manual calculation. Now we will be discussing the different types of examples and will calculate the value by both manually and by using an automatic excel format. So, let’s get started.
Example-2:
Lets a company manufacturing a toy product and below are the data given in several processes. so, calculate the DPMO, DPPM, DPO and DPU of individual processes and overall process by manually and by using the excel template. And also try to compare both solutions.
Process-1 Data Table:
| Total Defects | 30 nos |
| Total Defective parts | 20 nos |
| Defects opportunity per part | 3 |
| Total parts produced | 840 nos |
Process-2 Data Table:
| Total Defects | 102 nos |
| Total Defective parts | 80 nos |
| Defects opportunity per part | 4 |
| Total parts produced | 987 nos |
Process-3 Data Table:
| Total Defects | 17 nos |
| Total Defective parts | 16 nos |
| Defects opportunity per part | 3 |
| Total parts produced | 1003 nos |
Calculate the DPMO, DPPM, DPO and DPU of individual processes and overall processes by manually and by using the excel template?
Solution of Process-1:
DPU Formula = Total number of Defects / Total units
= 30/840
=0.0357
DPO (Defects Per Opportunity):
DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)
= 30/(840×3)
= 0.0119
DPMO (Defects per million opportunities):
DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000
= [30/(840×3)]x1000000
=11904.7
DPPM (Defective Parts Per Million):
DPPM Formula = (Total Defective parts / Total parts) x 1000000
= (20/840) x1000000
=23809.5
Similarly, Excel template calculation is given below as;
Solution of Process-2:
DPU (Defects per unit):
DPU Formula = Total number of Defects / Total units
= 102/987
= 0.1033
DPO (Defects Per Opportunity):
DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)
= 102/(987×4)
= 0.0258
DPMO (Defects per million opportunities):
DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000
= [102/(987×4)]x1000000
= 25835.86
DPPM (Defective Parts Per Million):
DPPM Formula = (Total Defective parts / Total parts) x 1000000
= (80/987) x1000000
= 81053.69
You can compare the answer with the below given Excel calculated value.
Solution of Process-3:
DPU (Defects per unit):
DPU Formula = Total number of Defects / Total units
= 17/1003
= 0.0169
DPO (Defects Per Opportunity):
DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)
= 17/1003×3
=0.0056
DPMO (Defects per million opportunities):
DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000
= [17/1003×3]x1000000
= 5649.7
DPPM (Defective Parts Per Million):
DPPM Formula = (Total Defective parts / Total parts) x 1000000
= [16/1003]x1000000
= 15952.14
Below are the excel calculation of the above value, you can match the value;
Overall Process DPMO Calculation:
For doing so we need a combined data table, so we have clubbed all the data of process-1,2 & 3 and given in below; the same part is produced in all 3 processes.
| Total Defects | 149 nos |
| Total Defective parts | 116 nos |
| Defects opportunity per part | 8 |
| Total parts produced | 2830 nos |
DPU (Defects per unit):
DPU Formula = Total number of Defects / Total units
= 149/2830
= 0.0526
DPO (Defects Per Opportunity):
DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)
= 149/2830×8
=0.00658
DPMO (Defects per million opportunities):
DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000
= [149/8×2830]x1000000
= 6581.27
DPPM (Defective Parts Per Million):
DPPM Formula = (Total Defective parts / Total parts) x 1000000
= (116/2830) x1000000
= 40989.39
[Excel Calculation of DPMO]
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TECHIEQUALITY
The Author is an Expert in Quality Management System, Operation Management, Business Excellence, Process Excellence, IATF 16949, ISO 9001, ISO 14001, ISO 45001, ISO 17025, TQM, TPM & QA. He is Certified as an IA for ISO 9001, IATF 16949, ISO 14001, ISO 17025 & ISO 45001 Standard.