First-Time Quality and Cost of Quality
topic
First-time quality (FTQ%) = (lots released to specification on first test) / (total lots tested) × 100. World-class FTQ for ring spinning: >95%. Cost of quality = prevention costs + appraisal costs + internal failure costs (rework, re-class) + external failure costs (claims, returns). Ring spinning quality costs typically represent 3–8% of total yarn revenue. Quality cost analysis identifies whether investment should go to prevention (process improvement) or appraisal (more testing).
Role
First-time quality and cost of quality analysis are the management tools that translate technical quality performance into business language understood by mill owners and investment committees. Demonstrating that a 2% improvement in FTQ% reduces quality costs by $200,000/year is more persuasive than showing CVm% improved by 0.5% — making this knowledge essential for textile engineers who want to influence investment decisions.