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Productivity
This indicator measures labour productivity and is based on the people hours required to
produce a single unit of volume. It is a measure of consumption and not cost.
Which Considers:
1. Should include all management, staff, and operators within the Make operation to produce
the agreed category unit of volume.
2. Casual and temporary labor FTE employed for production activities should also be included.
3. All indirect labor allocated to the production plant should be included, e.g. 50% of the Factory
Engineers time is allocated to the Hair manufacturing plant, therefore, this time should also be
included.
4. The average number of paid hours worked per employee, used to build up the total hours per
year, should exclude leave and paid holidays but include overtime.
5. Volume should consider only the agreed category unit e.g. Packed powder and not powder
transferred as an intermediate or packed soap and not noodles sold to 3rd party.
6. People included within Make should also include those involved in the following activities,
where they are under the responsibility of the factory manager:
Personnel involved in the handling and transfer of raw and pack materials to the point of
use,
Personnel involved in the handling and transfer of finished goods/intermediates from
process and packing hall.
Example:
Variable
Process 0 0 15
Fixed
Materials handling 0 2 10
Temporary 0 0 5
Indirects
Total people hours 898656
This measures the production floor utilization considering the impact of factory shutdowns on
availability.
Which Considers:
1. This is based on the packing hall, which is normally the bottleneck of the Make operation.
2. The loading time is the time available after shutdown losses have been removed.
3. Shutdown losses include the following: Holidays, Weekends, Factory Shutdown, No
production orders, Planned maintenance, and modifications.
4. Within factory shutdowns, the unavailable time due to work patterns should be included (e.g.
If the site works 6 days per week, the seventh day should be considered as part of the factory
shutdown)
5. For a plant with more than one packing line, the weighted average based on volume should
be calculated as shown in the example.
Example:
Volume Performance
This measure allows the evaluation of planned volume against actual. Capital investment and
manufacturing structures are projected based on these expectations, and any deviation should
be considered to redirect initial plans.
Which Considers:
1. Volume performance should be measured by SKU, category, and total plant. This should help
the factory to evaluate capacity utilization and return on capital investments specific to an SKU
or an innovation.
Example:
Liquid 50ml sample 200 200 100
Total
Volume = Volume produced in tonnes
Which Considers:
The volume should be consistent with the volume defined in Volume Performance but
expressed in engineering units of tonnes. Products not typically measured in units of weight
may ignore this measure.
Example:
Total
Volume = Volume produced in thousands of units.
Which Considers:
This volume should be consistent with the volume defined in Volume Performance but
expressed in thousands of units. Products not typically measured in weight units or single units
of production should report this number in the number of cases produced.
Example:
This is a measure of operational performance and is based on the TPM Cost of Production.
Which Considers:
1. The loading time is the time available once shutdown losses have been removed.
2. Shutdown losses include the following: Holidays, Weekends, Factory Shutdown, No
production orders, Planned maintenance, and modifications.
3. Within Factory shutdowns, the unavailable time due to work patterns should be included (e.g.
If the site works 6 days per week, the seventh day should be considered as part of the Factory
shutdown)
4. Downtime considers the following losses: Equipment breakdown, Changeovers, cutting blade
change (if appropriate), Startup, Ramp down, Management, and Operational Motion.
5. Standard cycle time is based on the designed or maximum speed, considering the bottleneck
in the line. It is the time to manufacture one unit e.g. 500 upm = 3.3 x 10-5 hours / unit
(1hour/(500*60 units))
6. When different products run on a given line at different speeds, then a weighted average
should be used to specify the speed of the line.
7. Where more than one line is being considered a weighted value should then be calculated.
8. Weighted averages should be calculated based on the relative volumes of each line:
Line 1 produced: 1000 Tonnes @ 65% OEE
Line 2 produced: 2000 Tonnes @ 45% OEE
Weighted average = (65%*1000/3000)+(45%*2000/3000) = 52%
9. Defect units consider waste products as well as the quantity of rework. This should consider
quality defects and rework relating to product and packaging material. Even if the product left
the factory and was later returned for not matching quality specifications.
10. Total product units processed should include defect units, therefore the figure for ‘Volume
produced’ should be all products including defect units.
11. The loss tree in the template asks for a defect related time, this is converted into units by
the calculation based on design speed.
12. Definitions for individual losses should be those considered within the TPM CoP.
13. A weighted OEE can be calculated for a Global based on volume.
Example:
Availability
– Planned modifications 0 0 0
– Management 75 75 150
Performance
Quality
Raw Material Yield = {(Actual Raw materials costs –Zero Based Raw
material costs) / Zero Based Raw material costs} * 100%
Which Considers:
1. This measure is focused on the Make process and therefore does not include obsolescence,
stock write-offs, etc.
2. The actual raw materials cost should not include consumables such as Bleaching earth,
catalysts which should be considered as part of the production cost.
3. The Zero-Based raw materials cost should not include the traditional BOM material wastage
allowances.
4. No allowance is to be made for over-packing, washouts, etc. as these are waste and
therefore should not be shown in the zero-based raw material consumption figure.
5. The raw materials cost should exclude material used for trials and pilot plant.
Example:
Packaging Material Yield = {(Actual packaging materials costs –Zero
Based packaging material costs) / Zero Based Packaging Materials Cost} *
100%
Which Considers:
1. This measure is focused on the Make process and therefore does not include obsolescence,
stock write-offs, etc.
2. The Zero-Based packaging Material costs should not include the traditional BOM material
wastage allowances.
3. No allowance is to be made for packing removed from poor product etc. as this is waste and
therefore should not be shown in the zero-based packaging material consumption figure.
4. The packaging materials cost should exclude material used for trials and pilot plant.
Example:
Rework Inventory
Rework
Inventory = The value in dollars of goods held not
shippable due to
quality issues.
Which Considers:
That product which is not immediately
meeting specification as a shippable finished good.
MTBF = Total
Operating Time / Number of breakdown events
Which Considers:
Delivery
SKU Complexity
Which Considers
Example
Volume Produced # of different SKUs
manufactured SKU Complexity
Note: The number of SKUs in the example assumes an overlap in the SKUs ran in each line. For
the total, this duplication should not be considered.
To measure the degree of flexibility and linkage of the Make Process within the overall supply
chain. The purpose of the measure is to track how closely Operating Units’ production
scheduling is to market needs. The more frequently that products are produced, the greater is
the flexibility to provide a rapid response with minimum stocks.
Portfolio Produced Weekly (PPW)% =(# Of unique SKU produced per week
X 100) / (# Of unique SKU in Portfolio)
Which Considers:
1. A unique SKU includes all standard and promotional items that are traded in the following
quarter to the period of evaluation.
2. SKU’s produced must be counted from the actual production every week
3. SKU’s Portfolio to be used considers the future three-month horizon.
4. Consolidation by month, quarter, year should be done as a weighted average by SKU volume.
Example:
#
SKU produced 23 37 34 62
PPW
% 37 60 55
Volume
(‘000 Units) 2500 3300 2870
Output
Reliability by SKU (%) = å (Plan – ABS (Actual – Plan)) * 100
å
Plan
Which Considers:
1. The Plan should be frozen in the week previous to the actual production week. No changes
requested by planning or by the factory should be accepted as changes to the original frozen
plan.
2. The plan comprises a period of 7 days of production (full week).
3. Consolidation by month, quarter, year, and Global should be done as a weighted average by
SKU volume.
4. Any product rejected for quality or hygiene incidents should not be recorded as production
output in this measure
5. Measurement at the plant should be on an SKU basis.
6. Factories should track the number of plan changes per week to ensure that causes for a poor
performance in this measure can be correctly attributed.
7. Output Reliability will only be calculated on the basis of packing lines, not in processing
operations.
Example:
Site 1 Week 1
OR(%) 93%
Site 1 Week 2
OR(%) 90%
Week 1 93 94
Week 2 90 97
Total Volume
255000 266000
OR(%) 91 96
Output Reliability Site 1, Week 1(OR)% = {(32000-2000)+(40000-
5000)+(43000-1000) * 100} / 115000 = 93%
To measure the activity occurring as changes to the “frozen” plant schedule after the schedule
has been “frozen” for the current short-term planning cycle.
Number of SC Planning
Schedule Changes = The difference between the
individual SKU count planned for in the
frozen schedule and the SKUs that
ran on the lines.
Which Considers:
1. The Plan (as set by SC Planning, not plant scheduling) should be frozen in the week previous
to the actual production week. Any changes requested by planning and jointly agreed should be
accepted as changes to the original frozen plan.
2. Any product rejected for quality or hygiene incidents should not be recorded as production
output in this measure
3. Measurement at the plant should be on an SKU basis.
4. The number of plan changes per week.
The number of SC Planning Schedule Changes will only be calculated based on packing lines,
not in processing operations.
Example:
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