One of the important decisions made when beginning to use the L2L Production Module is to determine what the Unit of Measure for your production data will be – the units that values for Pitch Demand and Pitch Target Quantities will be calculated in, as well as the units that the Pitch Actual and Pitch Defect quantities will be entered in. Depending on the production processes within your plant, your Units of Measure could potentially be Eaches (Individuals), Cases, Kilograms, or many other values.
Occasionally, your plant may contain multiple production processes which may have different preferred Units of Measure. Perhaps a bulk chemical process measures output in pounds while a packaging process measures output in cases. Within the L2L Production Module, you are welcome to use any Unit of Measure for your production data appropriate to your processes. There are, however, some important rules and considerations:
- Your Unit of Measure for Actual, Demand, Target, and Defects for a single line must be consistent: you cannot record Pitch Actual values in units of Kilograms and number Defects in units of Eaches on an individual production line.
- If you use different Units of Measure for different production Lines and/or Areas within your plant, understand that this will affect any aggregate metrics reported across those various Lines and/or Areas. This is essentially because you are attempting to combine measures for two different processes or products, like apples and oranges.
- Aggregate metrics across Lines and/or Areas with different Units of Measure will end up weighting the measure typically toward whichever Lines or Areas tend to have a larger value, i.e., toward Lines that record Actuals in Eaches at a value of 200 per pitch over Lines that record Actuals in Cases at a value of 15 per pitch. Therefore any Site-level reports would be subject to this skew.
- Aggregates of metrics which directly use production data values like Actual, Demand, Target, and Defects will be affected by this weighting issue. Additionally, aggregates of metrics which are adjacently based on a unit of measure, such as Cycle Time, which is entered as a per-unit value, will also be impacted. See the list below for all Production Statistics that would demonstrate a degree of impact when rolled up across various Units of Measure.
- To help easily aggregate “like” production data with “like” or segregate “apples” and “oranges” data in production reporting, consider using the Hierarchy structure or other asset grouping properties to your advantage. Maintaining the Lines that use different Units of Measure under different Areas within your site will allow you to easily run aggregate production reports for Lines of one unit type separately from Lines of another unit type. Another alternative that can be leveraged is Line Categories; a Line Category can be constructed for each Unit of Measure used in Production and then applied as a filter at the time Production Reports are generated.
Impacted Metrics
- Earned Hours (E-Hrs)
- (Actual * Planned Takt Time) / 3600
- Labor Minutes Per Unit (LMPU)
- (Operator Count * (Planned Production Minutes + Non Production Minutes)) / Actual
- Labor Hours Per Unit (LHPU)
- (Operator Count * (Planned Production Minutes + Non Production Minutes) / 60 ) / Actual
- OEE % (Overall Equipment Effectiveness)
- OA% * Quality% * Performance per Part%
- OA% = (Planned Production Minutes - Production Downtime Minutes) / Planned Production Minutes * 100
- Quality% = Actual / (Actual + Defect)
- Performance per Part% = (Cycle Time / Run Rate)
- Run Rate = (Planned Production Time - Production Downtime Minutes) / (Actual + Defect)
- OA% * Quality% * Performance per Part%
- Parts Produced per Man Hour (PPMH)
- (Actual + Defect) / (Operator Count * Planned Production Minutes)
- Parts Produced per Hour (PPH)
- Actual / Planned Production Minutes * 60
- Parts Produced per Minute (PPM)
- (Actual + Defect)/Planned Production Minutes
- PEFF
- Actual / Demand * 100
- Pace
- (Actual - Demand)
- Pitch Pace (Number of Pitches Ahead/Behind)
- (Actual-Demand) / (Average Demand To Date)
- Production Quality/Yield Percentage
- Actual / (Actual + Defect)
- Defect %
- Defect / (Actual + Defect) * 100
- Theoretical Efficiency
- Actual Parts Produced / Theoretical Parts per Pitch
- Theoretical Parts per Pitch = Planned Production Time in Seconds / Line Cycle Time in Seconds
- Actual Parts Produced / Theoretical Parts per Pitch
- Performance Per Part
- Cycle Time / Run Rate
- Run Rate = (Planned Production Time - Production Downtime Minutes) / (Actual + Defect)
- Cycle Time / Run Rate
- Time Per Unit
- Total Operator Count * (Planned Production Minutes - Production Downtime Minutes) / Actual Production
- Labor Efficiency
- Earned Minutes / Available Minutes
- Available Minutes = Planned Minutes - Planned Changeover Minutes
- Earned Minutes = Actual Parts * Planned Cycle Time / 60
- Planned Cycle Time = Planned Production Minutes / Demand * 60
- Earned Minutes / Available Minutes
- Reject %
- Reject / (Actual + Reject)
Non-Impacted Metrics
- OA % (Operational Availability)
- (Planned Production Minutes - Production Downtime Minutes) / Planned Production Minutes * 100
- Man Hours
- (Operator Count * Planned Production Minutes) / 60
- Non Productive Minutes
- Operator Count * Production Downtime Minutes
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