Vergence Business Associates - Manufacturing Consultants - Shift Production Summary Date: 17-Jan-09

Part Data Rate Per Hour Per Minute Cost Base Standard Cost % Overall Equipment Effectiveness and Cost Summary Time Reconciliation OEE Cross Check Weighted SHIFT OEE
IDEAL Cycle Time (Seconds): 15 IDEAL 240 4.00 Material $ 1.9000 64.35% Shift Availability Performance Quality OEE Cost Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
OEE - Current Index: 80.00% PLAN (OEE) 192 3.20 Labour $ 0.4651 15.75% Night 83.02% 89.64% 99.06% 73.72% $ 388.58 430.00 357.00 320.00 160.00 37.00 3.00 317.00 83.02% 89.64% 99.06% 73.72% 73.72% 27.7% 28.2% 30.1% 24.6%
Direct Labour Rate: $ 25.00 Labour $ 111.63 $ 1.86 Burden (Direct) $ 0.2500 8.47% Day 89.07% 93.21% 99.02% 82.21% $ 275.70 430.00 383.00 357.00 123.00 26.00 3.50 353.50 89.07% 93.21% 99.02% 82.21% 82.21% 29.7% 31.5% 33.6% 27.4%
Direct Labour (Count): 4 Burden (Indirect) $ 81.00 $ 1.35 Burden (Indirect) $ 0.3375 11.43% Afternoon 91.86% 95.25% 98.94% 86.57% $ 219.80 430.00 395.00 376.25 103.75 18.75 4.00 372.25 91.86% 95.25% 98.94% 86.57% 86.57% 30.6% 33.1% 35.3% 28.9%
Material Content (Per Part): $ 1.90 Process Cost $ 192.63 $ 3.21 Total Part Cost $ 2.9526 100.00% Total 87.98% 92.80% 99.00% 80.83% $ 884.09 1290.00 1135.00 1053.25 386.75 81.75 10.50 1042.75 87.98% 92.80% 99.00% 80.83% 80.83% 87.98% 92.80% 99.00% 80.83%
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate. Total Costs Standard Actual OEE Factor Availability Performance Quality Total Variance OEE Production Night Day Afternoon Totals % Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Minutes / Shift (8 hours): 480 Prorated = Total / Net Available Minutes Material $ 7,924.90 $ 8,004.70 99.00% $ - $ - $ 79.80 $ 79.80 $ 79.80 Total 1280 1428 1505 4213 100.00% Material 100.00% 100.00% 99.00% 99.00% $ 1.9000 $ 1.9191 $ (0.0191) 0.6004 0.6500
2 Paid 10 Minute Breaks: 20 Prorated Rate Factor: 480 / 430 = 1.1163 Labour $ 1,940.00 $ 2,400.00 80.83% $ 288.37 $ 152.09 $ 19.53 $ 460.00 $ 460.00 Scrap 5 5 9 19 0.45% Labour 87.98% 92.80% 99.00% 80.83% $ 0.4651 $ 0.5754 $ (0.1103) 0.1470 0.1949
1 Paid 20 Minute Meal Break: 20 Burden (Direct) $ 1,042.75 $ 1,053.25 99.00% $ - $ - $ 10.50 $ 10.50 $ 10.50 Hold 3 4 3 10 0.24% Burden Direct 100.00% 100.00% 99.00% 99.00% $ 0.2500 $ 0.2525 $ (0.0025) 0.0790 0.0855
Company / Plant Wide Meetings: 0 Prorated Labour Rate: $ 27.91 Burden (Indirect) $ 1,407.71 $ 1,741.50 80.83% $ 209.25 $ 110.36 $ 14.18 $ 333.79 $ 333.79 Test 4 5 4 13 0.31% Burden Indirect 87.98% 92.80% 99.00% 80.83% $ 0.3375 $ 0.4175 $ (0.0800) 0.1066 0.1414
5 Minute Shift Meeting: 5 Burden Costs Total $ 12,315.36 $ 13,199.45 93.30% $ 497.62 $ 262.46 $ 124.01 $ 884.09 $ 884.09 Accepted 1268 1414 1489 4171 99.00% Total Cost $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 $ 2.9526 $ 3.1646 $ (0.2120) 0.9330 1.0718
5 Minute Clean Up: 5 Direct (Parts) Indirect Total X-Check $ 12,315.36 $ 13,199.45 $ 884.09 96.23% 97.93% 99.00% 93.30% Cost Weighted % of Shift 99.06% 99.02% 98.94% 99.00% << Quality OEE (COST) 96.23% 97.93% 99.00% 93.30% $ 3.1646
Net Available Work Time: 430 $ 0.25 $ 81.00 $ 81.25 Actual Part Cost $ 3.1646 93.30% TEST Function $ 497.62 $ 262.46 $ 124.01 $ 884.09 OEE Factors % of Total 30.10% 33.56% 35.34% 99.00% << Weighted $ 3.0453 $ 2.9823 $ 2.9526 $ 0.2120 Cost Weighted
TEST Function
$ 0.9623 $ 0.9801 $ 0.9906 $ 12,701.83 $ 12,439.37 $ 12,315.36 $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 OEE Factors
Production Run Time Schedule Production Downtime Time Reconciliation (Minutes) Hourly OEE Weighted Hourly OEE
Shift
Start Stop Minutes IDEAL Plan (OEE) Total Scrap Hold Test Time Class Type Comments Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
Night
1 11:00 PM 11:05 PM 5.0 20 16 0 0 0 0 5.0 Planned Meeting Shift Meeting 5.00 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
11:05 PM 12:00 AM 55.0 220 176 145 1 2 2 16.0 Unplanned 55.00 39.00 36.25 18.75 2.75 1.25 35.00 70.9% 92.9% 96.6% 63.6% 63.6% 9.1% 10.2% 10.9% 8.1%
2 12:00 AM 1:00 AM 60.0 240 192 172 0 8.0 Unplanned 60.00 52.00 43.00 17.00 9.00 0.00 43.00 86.7% 82.7% 100.0% 71.7% 71.7% 12.1% 12.0% 13.4% 10.0%
3 1:00 AM 1:10 AM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
1:10 AM 2:00 AM 50.0 200 160 120 2 12.0 Unplanned 50.00 38.00 30.00 20.00 8.00 0.50 29.50 76.0% 78.9% 98.3% 59.0% 59.0% 8.8% 8.4% 9.2% 6.9%
4 2:00 AM 3:00 AM 60.0 240 192 210 0 1 1 5.0 Unplanned 60.00 55.00 52.50 7.50 2.50 0.50 52.00 91.7% 95.5% 99.0% 86.7% 86.7% 12.8% 14.7% 16.3% 12.1%
5 3:00 AM 3:20 AM 20.0 80 64 0 0 0 0 20.0 Planned Break 0.00 20.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
3:20 AM 4:00 AM 40.0 160 128 151 0 2.0 Unplanned 40.00 38.00 37.75 2.25 0.25 0.00 37.75 95.0% 99.3% 100.0% 94.4% 94.4% 8.8% 10.6% 11.8% 8.8%
6 4:00 AM 5:00 AM 60.0 240 192 202 1 5.0 Unplanned 60.00 55.00 50.50 9.50 4.50 0.25 50.25 91.7% 91.8% 99.5% 83.8% 83.8% 12.8% 14.1% 15.7% 11.7%
7 5:00 AM 5:20 AM 20.0 80 64 42 0 1 5.0 Unplanned 20.00 15.00 10.50 9.50 4.50 0.25 10.25 75.0% 70.0% 97.6% 51.3% 51.3% 3.5% 2.9% 3.2% 2.4%
5:20 AM 5:30 AM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
5:30 AM 6:00 AM 30.0 120 96 45 0 15.0 Unplanned 30.00 15.00 11.25 18.75 3.75 0.00 11.25 50.0% 75.0% 100.0% 37.5% 37.5% 3.5% 3.2% 3.5% 2.6%
8 6:00 AM 6:55 AM 55.0 220 176 193 1 5.0 Unplanned 55.00 50.00 48.25 6.75 1.75 0.25 48.00 90.9% 96.5% 99.5% 87.3% 87.3% 11.6% 13.5% 15.0% 11.2%
6:55 AM 7:00 AM 5.0 20 16 0 0 0 0 5.0 Planned Shift Clean Up 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Night TOTALS 480.0 1920 1536 1280 5 3 4 123.0 Unplanned 73.0 Net Available Time 430.0 357.00 320.00 160.00 37.00 3.00 317.00 83.02% 89.64% 99.1% 73.72% 73.72% 83.02% 89.64% 99.06% 73.72%
OEE Summary Material Labour Burden (Direct) Burden (Indirect) Total Loss Loss / Part %
Production Downtime Summary Labour Burden (Indirect) Operating Time Summary Labour Burden (Indirect) Production (Quantity) Summary Material Burden (Direct) Availability 83.02% $ - $ 135.81 $ - $ 98.55 $ 234.36 $ 0.1848 5.67% Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Scheduled Time: 480.0 Prorated Prorated IDEAL: 320.0 $ 595.35 $ 432.00 Total Produced: 1280 $ 2,432.00 $ 320.00 Performance 89.64% $ - $ 68.84 $ - $ 49.95 $ 118.79 $ 0.0937 2.87% Material 100.00% 100.00% 99.06% 99.06% $ 1.9000 $ 1.9180 $ (0.0180) 0.5830 0.6496
Planned Down Time: 50.0 Prorated Prorated Quality Loss: 3.0 $ 5.58 $ 4.05 Quality LOSS: 12 $ 22.80 $ 3.00 Quality 99.06% $ 22.80 $ 5.58 $ 3.00 $ 4.05 $ 35.43 $ 0.0279 0.86% Labour 83.02% 89.64% 99.06% 73.72% $ 0.4651 $ 0.6309 $ (0.1658) 0.1427 0.2137
Net Available Time: 430.0 $ 800.00 $ 580.50 Net IDEAL: 317.0 $ 589.77 $ 427.95 Total Accepted: 1268 $ 2,409.20 $ 317.00 OEE 73.72% $ 22.80 $ 210.23 $ 3.00 $ 152.55 $ 388.58 $ 0.3065 9.40% Burden Direct 100.00% 100.00% 99.06% 99.06% $ 0.2500 $ 0.2524 $ (0.0024) 0.0767 0.0855
Unplanned Down Time: 73.0 $ 135.81 $ 98.55 Actual: 357.0 $ 664.19 $ 481.95 Total Standard Operating Cost: $ 3,743.92 Total Efficiency: 90.60% Actual Cost / Part: $ 1.9180 $ 0.6309 $ 0.2524 $ 0.4578 $ 2.9526 Burden Indirect 83.02% 89.64% 99.06% 73.72% $ 0.3375 $ 0.4578 $ (0.1203) 0.1036 0.1551
$ 0.3065 90.60%
Actual Operating Time: 357.0 $ 664.19 $ 481.95 Performance Loss: 37.0 $ 68.84 $ 49.95 Total Actual Operating Cost: $ 4,132.50 Total Losses: $ 388.58 Actual Loss / Part: $ 0.0180 $ 0.1658 $ 0.0024 $ 0.1203 $ 3.2591 Total Cost $ 0.1848 $ 0.0937 $ 0.0279 $ 0.3065 $ 2.9526 $ 3.2591 $ (0.3065) 0.9060 1.1038
Loss Cross Check: 99.06% 73.72% 99.06% 73.72% OEE (COST) 94.33% 96.95% 99.06% 90.60% $ 3.2591
$ 3.0742 $ 2.9806 $ 2.9526 $ 0.3065 Cost Weighted
TEST Function OEE Factors
$ 0.1848 $ 0.0937 $ 0.0279 $ 0.3065

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Toronto, Ontario, Canada
 Vergence Business Associates - Manufacturing Consultants - Shift Production Summary Date: 17-Jan-09
Part Data Rate Per Hour Per Minute Cost Base Standard Cost % Overall Equipment Effectiveness and Cost Summary Time Reconciliation OEE Cross Check Weighted SHIFT OEE
IDEAL Cycle Time (Seconds): 15 IDEAL 240 4.00 Material $ 1.9000 64.35% Shift Availability Performance Quality OEE Cost Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
OEE - Current Index: 80.00% PLAN (OEE) 192 3.20 Labour $ 0.4651 15.75% Night 83.02% 89.64% 99.06% 73.72% $ 388.58 430.00 357.00 320.00 160.00 37.00 3.00 317.00 83.02% 89.64% 99.06% 73.72% 73.72% 27.7% 28.2% 30.1% 24.6%
Direct Labour Rate: $ 25.00 Labour $ 111.63 $ 1.86 Burden (Direct) $ 0.2500 8.47% Day 89.07% 93.21% 99.02% 82.21% $ 275.70 430.00 383.00 357.00 123.00 26.00 3.50 353.50 89.07% 93.21% 99.02% 82.21% 82.21% 29.7% 31.5% 33.6% 27.4%
Direct Labour (Count): 4 Burden (Indirect) $ 81.00 $ 1.35 Burden (Indirect) $ 0.3375 11.43% Afternoon 91.86% 95.25% 98.94% 86.57% $ 219.80 430.00 395.00 376.25 103.75 18.75 4.00 372.25 91.86% 95.25% 98.94% 86.57% 86.57% 30.6% 33.1% 35.3% 28.9%
Material Content (Per Part): $ 1.90 Process Cost $ 192.63 $ 3.21 Total Part Cost $ 2.9526 100.00% Total 87.98% 92.80% 99.00% 80.83% $ 884.09 1290.00 1135.00 1053.25 386.75 81.75 10.50 1042.75 87.98% 92.80% 99.00% 80.83% 80.83% 87.98% 92.80% 99.00% 80.83%
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate. Total Costs Standard Actual OEE Factor Availability Performance Quality Total Variance OEE Production Night Day Afternoon Totals % Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Minutes / Shift (8 hours): 480 Prorated = Total / Net Available Minutes Material $ 7,924.90 $ 8,004.70 99.00% $ - $ - $ 79.80 $ 79.80 $ 79.80 Total 1280 1428 1505 4213 100.00% Material 100.00% 100.00% 99.00% 99.00% $ 1.9000 $ 1.9191 $ (0.0191) 0.6004 0.6500
2 Paid 10 Minute Breaks: 20 Prorated Rate Factor: 480 / 430 = 1.1163 Labour $ 1,940.00 $ 2,400.00 80.83% $ 288.37 $ 152.09 $ 19.53 $ 460.00 $ 460.00 Scrap 5 5 9 19 0.45% Labour 87.98% 92.80% 99.00% 80.83% $ 0.4651 $ 0.5754 $ (0.1103) 0.1470 0.1949
1 Paid 20 Minute Meal Break: 20 Burden (Direct) $ 1,042.75 $ 1,053.25 99.00% $ - $ - $ 10.50 $ 10.50 $ 10.50 Hold 3 4 3 10 0.24% Burden Direct 100.00% 100.00% 99.00% 99.00% $ 0.2500 $ 0.2525 $ (0.0025) 0.0790 0.0855
Company / Plant Wide Meetings: 0 Prorated Labour Rate: $ 27.91 Burden (Indirect) $ 1,407.71 $ 1,741.50 80.83% $ 209.25 $ 110.36 $ 14.18 $ 333.79 $ 333.79 Test 4 5 4 13 0.31% Burden Indirect 87.98% 92.80% 99.00% 80.83% $ 0.3375 $ 0.4175 $ (0.0800) 0.1066 0.1414
5 Minute Shift Meeting: 5 Burden Costs Total $ 12,315.36 $ 13,199.45 93.30% $ 497.62 $ 262.46 $ 124.01 $ 884.09 $ 884.09 Accepted 1268 1414 1489 4171 99.00% Total Cost $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 $ 2.9526 $ 3.1646 $ (0.2120) 0.9330 1.0718
5 Minute Clean Up: 5 Direct (Parts) Indirect Total X-Check $ 12,315.36 $ 13,199.45 $ 884.09 96.23% 97.93% 99.00% 93.30% Cost Weighted % of Shift 99.06% 99.02% 98.94% 99.00% << Quality OEE (COST) 96.23% 97.93% 99.00% 93.30% $ 3.1646
Net Available Work Time: 430 $ 0.25 $ 81.00 $ 81.25 Actual Part Cost $ 3.1646 93.30% TEST Function $ 497.62 $ 262.46 $ 124.01 $ 884.09 OEE Factors % of Total 30.10% 33.56% 35.34% 99.00% << Weighted $ 3.0453 $ 2.9823 $ 2.9526 $ 0.2120 Cost Weighted
TEST Function
$ 0.9623 $ 0.9801 $ 0.9906 $ 12,701.83 $ 12,439.37 $ 12,315.36 $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 OEE Factors
Production Run Time Schedule Production Downtime Time Reconciliation (Minutes) Hourly OEE Weighted Hourly OEE
Shift
Start Stop Minutes IDEAL Plan (OEE) Total Scrap Hold Test Time Class Type Comments Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
Day
1 7:00 AM 7:05 AM 5.0 20 16 0 0 0 0 5.0 Planned Meeting Shift Meeting 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
7:05 AM 8:00 AM 55.0 220 176 145 1 2 2 15.0 Unplanned 55.00 40.00 36.25 18.75 3.75 1.25 35.00 72.7% 90.6% 96.6% 63.6% 63.6% 9.3% 9.5% 9.8% 8.1%
2 8:00 AM 9:00 AM 60.0 240 192 190 0 10.0 Unplanned 60.00 50.00 47.50 12.50 2.50 0.00 47.50 83.3% 95.0% 100.0% 79.2% 79.2% 11.6% 12.4% 13.3% 11.0%
3 9:00 AM 9:10 AM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
9:10 AM 10:00 AM 50.0 200 160 145 2 12.0 Unplanned 50.00 38.00 36.25 13.75 1.75 0.50 35.75 76.0% 95.4% 98.6% 71.5% 71.5% 8.8% 9.5% 10.0% 8.3%
4 10:00 AM 11:00 AM 60.0 240 192 217 0 1 1 5.0 Unplanned 60.00 55.00 54.25 5.75 0.75 0.50 53.75 91.7% 98.6% 99.1% 89.6% 89.6% 12.8% 14.2% 15.1% 12.5%
5 11:00 AM 11:20 AM 20.0 80 64 0 0 0 0 20.0 Planned Break 0.00 20.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
11:20 AM 12:00 PM 40.0 160 128 140 0 0.0 Unplanned 40.00 40.00 35.00 5.00 5.00 0.00 35.00 100.0% 87.5% 100.0% 87.5% 87.5% 9.3% 9.1% 9.8% 8.1%
6 12:00 PM 1:00 PM 60.0 240 192 230 1 1 0.0 Unplanned 60.00 60.00 57.50 2.50 2.50 0.50 57.00 100.0% 95.8% 99.1% 95.0% 95.0% 14.0% 15.0% 16.0% 13.3%
7 1:00 PM 1:20 PM 20.0 80 64 70 0 1 0.0 Unplanned 20.00 20.00 17.50 2.50 2.50 0.25 17.25 100.0% 87.5% 98.6% 86.2% 86.2% 4.7% 4.6% 4.8% 4.0%
1:20 PM 1:30 PM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
1:30 PM 2:00 PM 30.0 120 96 83 0 5.0 Unplanned 30.00 25.00 20.75 9.25 4.25 0.00 20.75 83.3% 83.0% 100.0% 69.2% 69.2% 5.8% 5.4% 5.8% 4.8%
8 2:00 PM 2:55 PM 55.0 220 176 208 1 1 0.0 Unplanned 55.00 55.00 52.00 3.00 3.00 0.50 51.50 100.0% 94.5% 99.0% 93.6% 93.6% 12.8% 13.6% 14.4% 12.0%
2:55 PM 3:00 PM 5.0 20 16 0 0 0 0 5.0 Planned Shift Clean Up 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Day TOTALS 480.0 1920 1536 1428 5 4 5 97.0 Unplanned 47.0 430.00 383.00 357.00 123.00 26.00 3.50 353.50 89.07% 93.21% 99.0% 82.21% 82.21% 89.07% 93.21% 99.02% 82.21%
OEE Summary Material Labour Burden (Direct) Burden (Indirect) Total Loss per Part %
Production Downtime Summary Labour Burden Operating Time Summary Labour Burden Production (Quantity) Summary Material Burden (Direct) Availability 89.07% $ - $ 87.44 $ - $ 63.45 $ 150.89 $ 0.1067 3.39% Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Scheduled Time: 480.0 Prorated Prorated IDEAL: 357.0 $ 664.19 $ 481.95 Total Produced: 1428 $ 2,713.20 $ 357.00 Performance 93.21% $ - $ 48.37 $ - $ 35.10 $ 83.47 $ 0.0590 1.88% Material 100.00% 100.00% 99.02% 99.02% $ 1.9000 $ 1.9188 $ (0.0188) 0.6036 0.6499
Planned Down Time: 50.0 Prorated Prorated Quality Loss: 3.5 $ 6.51 $ 4.73 Quality LOSS: 14 $ 26.60 $ 3.50 Quality 99.02% $ 26.60 $ 6.51 $ 3.50 $ 4.73 $ 41.34 $ 0.0292 0.93% Labour 89.07% 93.21% 99.02% 82.21% $ 0.4651 $ 0.5658 $ (0.1007) 0.1478 0.1916
Net Available Time: 430.0 $ 800.00 $ 580.50 Net IDEAL: 353.5 $ 657.67 $ 477.23 Total Accepted: 1414 $ 2,686.60 $ 353.50 OEE 82.21% $ 26.60 $ 142.33 $ 3.50 $ 103.28 $ 275.70 $ 0.1950 6.19% Burden Direct 100.00% 100.00% 99.02% 99.02% $ 0.2500 $ 0.2525 $ (0.0025) 0.0794 0.0855
Unplanned Down Time: 47.0 $ 87.44 $ 63.45 Actual: 383.0 $ 712.56 $ 517.05 Total Standard Operating Cost: $ 4,175.00 Total Efficiency: 93.81% Standard Costs: $ 1.9000 $ 0.4651 $ 0.2500 $ 0.3375 $ 2.9526 Burden Indirect 89.07% 93.21% 99.02% 82.21% $ 0.3375 $ 0.4105 $ (0.0730) 0.1072 0.1390
$ 0.1950 93.81%
Actual Operating Time: 383.0 $ 712.56 $ 517.05 Performance Loss: 26.0 $ 48.37 $ 35.10 Total Actual Operating Cost: $ 4,450.70 Total Losses: $ 275.70 Actual Cost: $ 1.9188 $ 0.5658 $ 0.2525 $ 0.4105 $ 3.1476 Total Cost $ 0.1067 $ 0.0590 $ 0.0292 $ 0.1950 $ 2.9526 $ 3.1476 $ (0.1950) 0.9381 1.0660
Loss Cross Check: 99.02% 82.21% 99.02% 82.21% OEE (COST) 96.61% 98.06% 99.02% 93.81% $ 3.1476
$ 3.0409 $ 2.9819 $ 2.9526 $ 0.1950 Cost Weighted
TEST Function
$ 0.1067 $ 0.0590 $ 0.0292 $ 0.1950 OEE Factors

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Toronto, Ontario, Canada
 Vergence Business Associates - Manufacturing Consultants - Shift Production Summary Date: 17-Jan-09
Part Data Rate Per Hour Per Minute Cost Base Standard Cost % Overall Equipment Effectiveness and Cost Summary Time Reconciliation OEE Cross Check Weighted SHIFT OEE
IDEAL Cycle Time (Seconds): 15 IDEAL 240 4.00 Material $ 1.9000 64.35% Shift Availability Performance Quality OEE Cost Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
OEE - Current Index: 80.00% PLAN (OEE) 192 3.20 Labour $ 0.4651 15.75% Night 83.02% 89.64% 99.06% 73.72% $ 388.58 430.00 357.00 320.00 160.00 37.00 3.00 317.00 83.02% 89.64% 99.06% 73.72% 73.72% 27.7% 28.2% 30.1% 24.6%
Direct Labour Rate: $ 25.00 Labour $ 111.63 $ 1.86 Burden (Direct) $ 0.2500 8.47% Day 89.07% 93.21% 99.02% 82.21% $ 275.70 430.00 383.00 357.00 123.00 26.00 3.50 353.50 89.07% 93.21% 99.02% 82.21% 82.21% 29.7% 31.5% 33.6% 27.4%
Direct Labour (Count): 4 Burden (Indirect) $ 81.00 $ 1.35 Burden (Indirect) $ 0.3375 11.43% Afternoon 91.86% 95.25% 98.94% 86.57% $ 219.80 430.00 395.00 376.25 103.75 18.75 4.00 372.25 91.86% 95.25% 98.94% 86.57% 86.57% 30.6% 33.1% 35.3% 28.9%
Material Content (Per Part): $ 1.90 Process Cost $ 192.63 $ 3.21 Total Part Cost $ 2.9526 100.00% Total 87.98% 92.80% 99.00% 80.83% $ 884.09 1290.00 1135.00 1053.25 386.75 81.75 10.50 1042.75 87.98% 92.80% 99.00% 80.83% 80.83% 87.98% 92.80% 99.00% 80.83%
ALL Labour and Burden costs are based on Machine Hours at the Standard or IDEAL Rate. Total Costs Standard Actual OEE Factor Availability Performance Quality Total Variance OEE Production Night Day Afternoon Totals % Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Minutes / Shift (8 hours): 480 Prorated = Total / Net Available Minutes Material $ 7,924.90 $ 8,004.70 99.00% $ - $ - $ 79.80 $ 79.80 $ 79.80 Total 1280 1428 1505 4213 100.00% Material 100.00% 100.00% 99.00% 99.00% $ 1.9000 $ 1.9191 $ (0.0191) 0.6004 0.6500
2 Paid 10 Minute Breaks: 20 Prorated Rate Factor: 480 / 430 = 1.1163 Labour $ 1,940.00 $ 2,400.00 80.83% $ 288.37 $ 152.09 $ 19.53 $ 460.00 $ 460.00 Scrap 5 5 9 19 0.45% Labour 87.98% 92.80% 99.00% 80.83% $ 0.4651 $ 0.5754 $ (0.1103) 0.1470 0.1949
1 Paid 20 Minute Meal Break: 20 Burden (Direct) $ 1,042.75 $ 1,053.25 99.00% $ - $ - $ 10.50 $ 10.50 $ 10.50 Hold 3 4 3 10 0.24% Burden Direct 100.00% 100.00% 99.00% 99.00% $ 0.2500 $ 0.2525 $ (0.0025) 0.0790 0.0855
Company / Plant Wide Meetings: 0 Prorated Labour Rate: $ 27.91 Burden (Indirect) $ 1,407.71 $ 1,741.50 80.83% $ 209.25 $ 110.36 $ 14.18 $ 333.79 $ 333.79 Test 4 5 4 13 0.31% Burden Indirect 87.98% 92.80% 99.00% 80.83% $ 0.3375 $ 0.4175 $ (0.0800) 0.1066 0.1414
5 Minute Shift Meeting: 5 Burden Costs Total $ 12,315.36 $ 13,199.45 93.30% $ 497.62 $ 262.46 $ 124.01 $ 884.09 $ 884.09 Accepted 1268 1414 1489 4171 99.00% Total Cost $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 $ 2.9526 $ 3.1646 $ (0.2120) 0.9330 1.0718
5 Minute Clean Up: 5 Direct (Parts) Indirect Total X-Check $ 12,315.36 $ 13,199.45 $ 884.09 96.23% 97.93% 99.00% 93.30% Cost Weighted % of Shift 99.06% 99.02% 98.94% 99.00% << Quality OEE (COST) 96.23% 97.93% 99.00% 93.30% $ 3.1646
Net Available Work Time: 430 $ 0.25 $ 81.00 $ 81.25 Actual Part Cost $ 3.1646 93.30% TEST Function $ 497.62 $ 262.46 $ 124.01 $ 884.09 OEE Factors % of Total 30.10% 33.56% 35.34% 99.00% << Weighted $ 3.0453 $ 2.9823 $ 2.9526 $ 0.2120 Cost Weighted
TEST Function
$ 0.9623 $ 0.9801 $ 0.9906 $ 12,701.83 $ 12,439.37 $ 12,315.36 $ 0.1193 $ 0.0629 $ 0.0297 $ 0.2120 OEE Factors
Production Run Time Schedule Production Downtime Time Reconciliation (Minutes) Hourly OEE Weighted Hourly OEE
Shift
Start Stop Minutes IDEAL Plan (OEE) Total Scrap Hold Test Time Class Type Comments Available Operating Earned Lost Performance Quality Net Earned Availability Performance Quality OEE Net OEE Availability Performance Quality OEE
Afternoon
1 3:00 PM 3:05 PM 5.0 20 16 0 0 0 0 5.0 Planned Meeting Shift Meeting 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0%
3:05 PM 4:00 PM 55.0 220 176 198 1 2 2 5.0 Unplanned 55.00 50.00 49.50 5.50 0.50 1.25 48.25 90.9% 99.0% 97.5% 87.7% 87.7% 11.6% 12.5% 12.8% 11.2%
2 4:00 PM 5:00 PM 60.0 240 192 224 1 0.0 Unplanned 60.00 60.00 56.00 4.00 4.00 0.25 55.75 100.0% 93.3% 99.6% 92.9% 92.9% 14.0% 14.2% 14.8% 13.0%
3 5:00 PM 5:10 PM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0%
5:10 PM 6:00 PM 50.0 200 160 138 2 15.0 Unplanned 50.00 35.00 34.50 15.50 0.50 0.50 34.00 70.0% 98.6% 98.6% 68.0% 68.0% 8.1% 8.7% 9.0% 7.9%
4 6:00 PM 7:00 PM 60.0 240 192 227 0 1 1 0.0 Unplanned 60.00 60.00 56.75 3.25 3.25 0.50 56.25 100.0% 94.6% 99.1% 93.8% 93.8% 14.0% 14.4% 15.0% 13.1%
5 7:00 PM 7:20 PM 20.0 80 64 0 0 0 0 20.0 Planned Break 0.00 20.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0%
7:20 PM 8:00 PM 40.0 160 128 148 0 0.0 Unplanned 40.00 40.00 37.00 3.00 3.00 0.00 37.00 100.0% 92.5% 100.0% 92.5% 92.5% 9.3% 9.4% 9.8% 8.6%
6 8:00 PM 9:00 PM 60.0 240 192 232 3 0.0 Unplanned 60.00 60.00 58.00 2.00 2.00 0.75 57.25 100.0% 96.7% 98.7% 95.4% 95.4% 14.0% 14.7% 15.2% 13.3%
7 9:00 PM 9:20 PM 20.0 80 64 38 0 1 10.0 Unplanned 20.00 10.00 9.50 10.50 0.50 0.25 9.25 50.0% 95.0% 97.4% 46.3% 46.3% 2.3% 2.4% 2.5% 2.2%
9:20 PM 9:30 PM 10.0 40 32 0 0 0 0 10.0 Planned Break 0.00 10.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0%
9:30 PM 10:00 PM 30.0 120 96 107 0 0.0 Unplanned 30.00 30.00 26.75 3.25 3.25 0.00 26.75 100.0% 89.2% 100.0% 89.2% 89.2% 7.0% 6.8% 7.1% 6.2%
8 10:00 PM 10:55 PM 55.0 220 176 193 2 5.0 Unplanned 55.00 50.00 48.25 6.75 1.75 0.50 47.75 90.9% 96.5% 99.0% 86.8% 86.8% 11.6% 12.2% 12.7% 11.1%
10:55 PM 11:00 PM 5.0 20 16 0 0 0 0 5.0 Planned Shift Clean Up 0.00 0.00 5.00 0.00 0.00 0.00 0.0% 0.0% 0.0% 0.0% 0.0%
Afternoon TOTALS 480.0 1920 1536 1505 9 3 4 85.0 Unplanned 35.0 430.00 395.00 376.25 103.75 18.75 4.00 372.25 91.86% 95.25% 98.9% 86.57% 86.57% 91.86% 95.25% 98.94% 86.57%
OEE Summary Material Labour Burden (Direct) Burden (Indirect) Total Loss per Part %
Production Downtime Summary Labour Burden Operating Time Summary Labour Burden Production (Quantity) Summary Material Burden (Direct) Availability 91.86% $ - $ 65.12 $ - $ 47.25 $ 112.37 $ 0.0755 2.43% Cost Base Availability Performance Quality OEE Rate Standard Cost Actual Cost Gain (Loss) Weighted Multiplier
Total Scheduled Time: 480.0 Prorated Prorated IDEAL: 376.3 $ 700.00 $ 507.94 Total Produced: 1505 $ 2,859.50 $ 376.25 Performance 95.25% $ - $ 34.88 $ - $ 25.31 $ 60.20 $ 0.0404 1.30% Material 100.00% 100.00% 98.94% 98.94% $ 1.9000 $ 1.9204 $ (0.0204) 0.6129 0.6504
Planned Down Time: 50.0 Prorated Prorated Quality Loss: 4.0 $ 7.44 $ 5.40 Quality LOSS: 16 $ 30.40 $ 4.00 Quality 98.94% $ 30.40 $ 7.44 $ 4.00 $ 5.40 $ 47.24 $ 0.0317 1.02% Labour 91.86% 95.25% 98.94% 86.57% $ 0.4651 $ 0.5373 $ (0.0722) 0.1500 0.1820
Net Available Time: 430.0 $ 800.00 $ 580.50 Net IDEAL: 372.3 $ 692.56 $ 502.54 Total Accepted: 1489 $ 2,829.10 $ 372.25 OEE 91.86% $ 30.40 $ 107.44 $ 4.00 $ 77.96 $ 219.80 $ 0.1476 4.76% Burden Direct 100.00% 100.00% 98.94% 98.94% $ 0.2500 $ 0.2527 $ (0.0027) 0.0806 0.0856
Unplanned Down Time: 35.0 $ 65.12 $ 47.25 Actual: 395.0 $ 734.88 $ 533.25 Total Standard Operating Cost: $ 4,396.45 Total Efficiency: 95.24% Standard Costs: $ 1.9000 $ 0.4651 $ 0.2500 $ 0.3375 $ 2.9526 Burden Indirect 91.86% 95.25% 98.94% 86.57% $ 0.3375 $ 0.3899 $ (0.0524) 0.1089 0.1320
$ 0.1476 95.24%
Actual Operating Time: 395.0 $ 734.88 $ 533.25 Performance Loss: 18.8 $ 34.88 $ 25.31 Total Actual Operating Cost: $ 4,616.25 Total Losses: $ 219.80 Actual Cost: $ 1.9204 $ 0.5373 $ 0.2527 $ 0.3899 $ 3.1002 Total Cost $ 0.0755 $ 0.0404 $ 0.0317 $ 0.1476 $ 2.9526 $ 3.1002 $ (0.1476) 0.9524 1.0500
Loss Cross Check: 98.94% 86.57% 98.94% 86.57% OEE (COST) 97.57% 98.66% 98.94% 95.24% $ 3.1002
$ 3.0248 $ 2.9843 $ 2.9526 $ 0.1476 Cost Weighted
TEST Function
$ 0.0755 $ 0.0404 $ 0.0317 $ 0.1476 OEE Factors

Printed: 07/06/2017 / 22:08:35 Vergence Business Associates - Manufacturing Consultants Page 3 of 10

Toronto, Ontario, Canada
 Factor World Class Downtime
Availability 90.0% CLASS Planned
Performance 95.0% Planned Meeting
Quality 99.5% Unplanned Clean Up
World Class 85.1% Other Break
PM
Change Over
Setup
Other
wntime
Unplanned
Material
Labour
Quality
Stock Out
Change Over Vergence Business Associates - Manufacturing Consultants
Setup Redge Semplonius - President & CEO
Containers Toronto, Ontario, Canada
Process Lean Execution Advanced Strategy Team
Equipment Providing Solutions in Real Time for Real Results
Tooling Focus for Success
Maintenance Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO9001)
Utilities
Other
 - Manufacturing Consultants
- President & CEO
ario, Canada
nced Strategy Team
al Time for Real Results
Success
ality Systems (TS-16949, ISO9001)
 Vergence Business Associates - Manufacturing Consultants
Redge Semplonius - President & CEO
Toronto, Ontario, Canada
Lean Execution Advanced Strategy Team
Providing Solutions in Real Time for Real Results
Focus For Success
Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO9001)

Instructions

The spreadsheet is not as complex as it may appear at first glance. The input portion is what we would consider typical of a no
calculations are all based on the concepts that we have introduced through our book and on line Blog (http://www.leanexecuti

Data is entered into the "white" cells.

Burden Costs

Our spreadsheet provides for Direct and Indirect Burden costs. Identifying these costs requires careful consideration to costs t
For the purposes of the model, we could create calculations to consider the direct burden allocation per part, however, we rec

Excel Time Calculations

The difference between two TIMES or DATES is easily calculated by subtracting one from the other, however, Excel does not all
The shift report is based on consecutive hours worked and considers the change date change at MIDNIGHT to be the start of th

Daily Rates Hours Per Day

Hours / Day 24 24
Minutes / Hour 60 1440
Seconds / Minute 60 86400

We use this knowledge to calculate the difference between the start and stop times indicated on the shift report based on "co

All calculations on our spreadsheet are based minutes and seconds. A more refined resolution could be used if necessary, how

Vergence Business Associates - Manufacturing Consultants

Redge Semplonius - President & CEO
Toronto, Ontario, Canada
Lean Execution Advanced Strategy Team
Providing Solutions in Real Time for Real Results
Focus For Success
Lean Manufacturing, Six Sigma, Quality Systems (TS-16949, ISO9001)
 http://www.leanexecution.wordpress.com
http://www.leanexecution.tk

uld consider typical of a normal production or manafucturing operation. The resulting

g (http://www.leanexecution.wordpress.com)

ul consideration to costs that are truly part related versus operational or facility oriented.
per part, however, we recommend confirming your intentions with your Finance department.

owever, Excel does not allow "negative" values.

NIGHT to be the start of the next day.

shift report based on "consecutive" hours worked.

d be used if necessary, however, the time base chosen seems to fit most industry applications.
 Vergence Business Associates - Manufacturing Consultants
Toronto, Ontario, Canada - 14-Jun-09

Vergence Business Associates - Toronto, Ontario, Canada

Feedback

If you have any questions, comments, suggestions, or concerns with this template, please feel free
to send an e-mail to:
Vergence.Consultants@gmail.com
or
LeanExecution@gmail.com

Topics

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Advanced Lean Execution Team
Toronto, Ontario, Canada
a future post.