Improving First Piece Yield ( FPY) in Forging Units Using IATF 16949 Quality Tools.

First Piece Yield (FPY) is a key performance indicator in manufacturing, particularly in the forging industry where high-temperature operations and heavy-duty equipment increase the risk of defects. This study explores how tools prescribed by the IATF 16949:2016 standard can be applied to improve FPY in forging processes. The paper demonstrates how implementing structured quality planning methods, statistical tools, and systematic problem-solving approaches significantly enhances first-time-right production. A case study from a forging plant is also presented to validate the impact of APQP, Control Plans, PFMEA, and SPC in reducing first-piece defects and achieving sustainable quality improvements.