Performance is a metric used to measure efficiency of a production line. It is also used in the OEE calculation. Performance is available for customers who are entering data in the Production Engine. Like OEE, Line cycle times must be defined for each line for this metric to work.
Calculating Performance for a Pitch
We use the following industry-standard formula to calculate Performance for an individual pitch:
Performance = (Ideal Cycle Time / Run Rate) * 100
Cycle Time comes from the Line Cycle Time definitions. The pitch Actual Product and Actual Operator count is used to look up the Cycle Time value.
Calculating Run Rate
Run Rate = ((Planned Production Time - Downtime) *60) / (Actual + Scrap) )* 100
Note: To use the Run Rate with the cycle time, you'll need to convert the minutes into seconds. This can be done simply by multiplying your (planned production minutes - downtime minutes) by 60.
Calculating Performance for multiple pitches
When calculating Performance for more than one pitch the above formula does not work. This is due to the variance in pitch duration and cycle times. In order to calculate Performance for more than one pitch, it must be broken into its individual components. This allows us calculate Performance based off of aggregate data. This is how we calculate Performance for more than one pitch:
Performance = (sum(Pitch Actual Parts) + sum(Pitch Scrap Parts)) / sum(Pitch Theoretical Parts)
Pitch Theoretical Parts = Pitch Available Time / Pitch Ideal Cycle Time
Pitch Available Time = Pitch Planned Production Minutes - Pitch Downtime
As you can see, this formula calculates Performance using theoretical data and actual data, just like the industry standard formula above. When we compare the results of each formula on a pitch basis, they are identical. The benefit of the second formula is that it provides a meaningful metric when calculating Performance on more than one pitch.
- Pro-Tip Regarding Performance (PPP%) and the Redistribute button functionality: Note that Redistribute uses Cycle Time to set demand. If the demand is set manually, and then the Redistribute function is used, the system will change to planning based on the Cycle Time for the line or cell unless you change the 'schedule by' to quantity.
- Ideal Cycle Time is used to calculate Performance (PPP%). The system will look up Cycle Time based off of the number of operators and the current product when it is updated with Actual, Scrap, or Downtime. If your Performance (PPP%) number looks off, it is likely because of pitches that have no Actual, Scrap, or Downtime and therefore, no Cycle Time. You can remedy this by doing one of the following:
- Inactivate Pitches with no Actual, Scrap and Downtime. Most likely, the line wasn't running, and the pitch just needs to be inactivated to reflect that. If you find yourself doing this often, you may consider updating your Pitch Template.
- Save "0" actual to the pitch. This will set the Cycle Time on the pitch, and fix the Performance (PPP%) metric.
- You will want to use raw data if you are trying to match our calculations. For example, downtime is rounded on the pitch board, it's very likely that the number isn't 20 but 19.81.
- If you are calculating performance from raw pitch data, you can use this formula:
- Performance = ideal cycle time/ (sum(Planned Production Minutes) - sum(Pitch Downtime) *60/ (sum(Pitch Actual Parts) + sum(Pitch Scrap Parts)) *100