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 TemplateDOWNLOAD

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;

DPMO Calculation

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 Defects30 nos
Total Defective parts20 nos
Defects opportunity per part3
Total parts produced840 nos

Process-2 Data Table:

Total Defects102 nos
Total Defective parts80 nos
Defects opportunity per part4
Total parts produced987 nos

Process-3 Data Table:

Total Defects17 nos
Total Defective parts16 nos
Defects opportunity per part3
Total parts produced1003 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;

excel formula

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.

DPMO Calculation

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;

DPMO Calculation

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 Defects149 nos
Total Defective parts116 nos
Defects opportunity per part8
Total parts produced2830 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

Overall

[Excel Calculation of DPMO]

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