KPIs (Key Performance Indicators), or Key Performance Indicators, are metrics used to monitor and evaluate the performance of industrial processes, quality tests, production lines, and even technical teams.
They allow for data-driven decisions, identify bottlenecks, optimize processes, and ensure continuous improvement — one of the pillars of success in modern industrial environments.
🧭 What are KPIs used for in practice?
- Monitor efficiency and productivity in real-time
- Evaluate product and process quality
- Identify recurring failures or statistical deviations
- Facilitate quick and objective decision-making
- Generate transparency with traceable and comparable reports
Without KPIs, quality and production management is based on intuition, not facts.
Main KPIs used in industrial environments
🔁 FPY (First Pass Yield)
Percentage of products approved on the first pass through the test, without rework.
Indicates process efficiency and test stability (read the article about FPY).
📊 CPK / PPK (Process Capability)
Evaluate the dispersion and centralization of data in relation to specified limits.
Essential for validating critical processes with tight tolerances:
📈 MTBF / MTTR (Reliability and Maintenance)
- MTBF (Mean Time Between Failures): average time between equipment failures
- MTTR (Mean Time To Repair): average time to repair a failure
Applicable to test benches, production lines, robots, or instruments. - (read the article about MTBF / MTTR)
⏱️ Cycle Time
Time required to complete a production or test unit.
Directly impacts production capacity and cell efficiency.
(read the article about cycle time)
🚨 Top Failures / Pareto of Failures
List of the most frequent and impactful failures in the process.
Basis for root cause analysis and action plans (read the article about Top Failures / Pareto of Failures).
📦 OQC / OBA Final Compliance
Compliance KPIs in final tests before shipment:
- % of rejection due to aesthetics
- % of missing components or accessories
- % of products rejected by batch
How AJOLLY Testing applies KPIs in test systems
AJOLLY Testing integrates the main KPIs directly into test software, databases, and technical dashboards. The data are:
- Automatically captured by instruments, sensors, and software
- Stored with full traceability (series, batch, operator, station)
- Presented in graphs, tables, and filterable reports
- Available for integration with MES, ERP, Power BI, or web dashboards
Examples of KPI Dashboards
| Indicator | Visualization |
|---|---|
| FPY by shift | Stacked bar chart |
| CPK by parameter | Histogram with Gaussian curve |
| Top 5 failures | Real-time Pareto chart |
| Cycle time | Timeline with upper limit |
| MTBF | Table by equipment or station |
Benefits of KPIs with AJOLLY Testing
✅ Fact-based decisions, not assumptions
🔧 Reduction of recurring failures and rework
📈 Solid foundation for continuous improvement (PDCA, Six Sigma)
📋 Full support for audits and certifications (ISO, FDA, IATF)
🔗 Integration with production, engineering, quality, and management systems