Category
Manufacturing
Definition
Objective
Calculation
Roll up Formula:
Weights = Production Accuracy x Production Plan
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
Objective
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.
Category
Metric Level
Manufacturing
Tier III
Definition
Objective
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
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 :
65%-95%
World Class
> 95%
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
Production run
Hours
at Rated Speed