KPI's Production Performance to Plan

Category

Manufacturing

Definition

An absolute measure of Manufacturing Planned Production vs. Actual

Production

Objective

A measure of the effectiveness of manufacturing to meet planned

requirements both in terms of time and quantity.

Calculation

Roll up Formula:
Weights = Production Accuracy x Production Plan

Production Plan is the cases planned (published production schedule

released 12-24 hours ahead of the actual execution).
Production Actual is the cases produced and accepted off the line.

Line Direct Labor Productivity

Calcula
tion

Direct Labor Hours is the sum of all hours worked including overtime by direct
labor on the line regardless of employment status.

Product-to-Product

Definition

Measurement of efficiency of a changeover.

Objective

Utilized to determine changeovers are being performed as efficiently as possible.

Calculation

Actual changeover is the time from the last bottle produced on the filler in one
flavor, to the first good bottle produced in the next flavor.
Normal changeover is the estimated standard time from the last bottle produced on
the filler in one flavor, to the first good bottle produced in the next flavor.
First good bottle is the first bottle produced from the filler after quality checks are
approved.
Estimated standard time is the time that is benchmarked and approved by
production management as the minimum best time the changeover can be
performed.

Right First Time

Category

Metric Level

Manufacturing

Tier III

Definition

Measurement of the quality of product at startup of the line.

Objective

Utilized to determine changeovers are being performed as efficiently as

possible.

Calculation

# of good startups is the total number of all startups after changeover where
quality checks have been approved.
# of total startups is total number of all startups after changeover.

PM/CM Ratio

Category

Metric Level

Manufacturing Maintenance

Tier III

Definition

A ratio of the PMs or Inspections hours spent vs. the total hours spent on Corrective and
Preventive Maintenance and Inspections.

Objective

To measure the effectiveness of the planning/scheduling and PM programs and its influence
on corrective maintenance.

Calculation

Mechanical Efficiency - Maintenance

Calculation
(Scheduled Run Hours Equipment Loss Hours)/Scheduled Run Hours

Equipment Loss: mechanical loss in, processing, packaging equipment and utilities.
If you are in a plant using MRM for downtime tracking, the calculation is :

1- (EPL/Scheduled Run Time)

Industry Average

65%-95%

World Class

> 95%

Unconstrained System Line Efficiency

Calculation

Theoretical units @ Unconstrained Line Speed is based on the O.E.M. filler line speed or
faster times the total time scheduled to run. (Does not include any scheduled downtime)
Total Units Produced is the total number of quality units produced.

Note: Use the above calculation for one production run of one package size. To determine
the overall USLE of a production line or multiple production lines in a plant, production
output must be converted into Equivalent Hours Produced at Rated Speed.

USLE % of one

Scheduled

Equivalent Hours Produced

Production run

Hours

at Rated Speed

The summation of Equivalent Hours Produced at Rated Speed divided by the

summation of Scheduled hours will be the USLE for a production line running packages
at different speeds or a production plant running multiple production lines. See USLE
Example on the next page for how to do this.