Reduce Asset Waste and Increase Output
Identify where machines, labor, and material flow lose efficiency. Find losses and recover output without new capital investment.
Increase Productivity
Increase production output across the system. Improve flow between processes, and keep resources running efficiently to produce more finished goods.
Weekly throughput (units / week)
Throughput
575 units / wk
+37.1%
Production rate
11.98 units / hr
+3.27
Makespan
39 hrs
(10) hrs
Capacity Utilization
Get more output from existing machines, labor, and floor space. Balance workloads, and reduce setup delays without adding new resources.
Machine utilization by line (%)
Average utilization
83.4%
+23.4 pts
Machine idle time
3 hrs / day
(4) hrs
Machine load balance index
0.93
+0.21
Setup time ratio
6.1%
(8.4) pts of available time
Workforce Allocation
Assign workers where they are needed most. Balance workloads across workstations, reduce idle time and overtime.
Shift hours composition (8-hr shift)
Labor utilization
92.5%
+18.3 pts
Idle labor time
4 hrs / shift
(2) hrs
Workforce cost
18.4K wk
(9.1)%
Yield Optimization
Increase the share of finished goods that meet quality standards. Cut material waste per unit shipped.
First-pass yield composition
86%
Before
96%
After
First-pass yield
96.0%
+10.0 pts
Work-in-process
142 units
(58)
Average flow time
4 hrs
(1) hr