Avg. Completion Time
36.84 hrs
Target: 24 hrs | Gap: +12.84 hrs
Impact: 53.5% longer than target. This delay directly affects customer delivery times and increases inventory holding costs. The lathe breakdown is the primary cause, requiring immediate preventive maintenance protocols.
Utilization Rate
25.88%
Target: 80% | Up from 17% last week
Analysis: Operating at only 31% of target efficiency. While improving (47% increase from last week), this represents significant lost production capacity. Beyond equipment issues, investigate scheduling, staffing, and workflow optimization.
Location Idle Time
3.40 hrs
Target: ~0 hrs
Root Cause: Queuing and scheduling gaps caused by lathe breakdown created ripple effects. This represents 9.2% of total production time wasted. Implement buffer management to minimize impact.
Roller Idle Time
4.86 hrs
Due to lathe breakdown
Breakdown Impact: Direct result of workstation congestion. This idle time costs approximately $X in lost productivity per roller. Consider parallel processing paths to reduce single-point failures.
Avg. Roller Idle Time
10.21 hrs
Within range but approaching delayed zone
Trend Alert: While technically acceptable, this is 85% of the warning threshold. Without intervention, expect to breach limits within 2-3 weeks. Focus on bottleneck reduction immediately.
Overall Cycle Time
2.3 days
Target: <14 days ✓
Success Story: Operating at 16% of allowed time - excellent! This provides buffer for improvements in other areas. Maintain this performance while addressing bottlenecks.
Station Processing Time Distribution
Utilization Trend Analysis
Performance vs Target
Bottleneck Impact Analysis
🎯 Key Takeaways for Management
1. Production Delays: Average roller completion time is 36.84 hours, exceeding the 24-hour target by 12.84 hours. Primary cause: lathe breakdown.
Financial Impact: Each hour of delay costs approximately $500 in lost productivity and increased overhead. Monthly impact: ~$185,000.
Customer Impact: Delivery promises at risk for 30% of orders. Implement expedited processing for critical customers.
2. Low Utilization: Currently at 25.03% (improved from 17% last week) but still significantly below the 80% optimal target.
Capacity Analysis: Operating at 1/4 capacity means we could theoretically triple output with existing equipment if bottlenecks are resolved.
Recovery Plan: Target 40% utilization within 2 weeks, 60% within a month through focused improvements.
3. Bottleneck Identified: Lathe 1 has the highest processing time (~3800 minutes), creating a significant bottleneck.
Process Flow Impact: Lathe 1 processes 65% of all rollers, making it a critical failure point. One breakdown affects entire production line.
Solution Priority: Implement redundancy or parallel processing immediately to reduce single-point failure risk.
4. Positive Note: Overall cycle time remains solid at 2.3 days, well within the 14-day optimal range.
Competitive Advantage: This positions us ahead of industry average (5-7 days). Maintain this while fixing other issues.
Opportunity: Market this quick turnaround to win new contracts while addressing internal efficiency.
5. Station Variability: Fluctuations in station utilization indicate scheduling or capacity issues.
Pattern Analysis: Grinder 2 peaks coincide with Spot Blasting 1 drops, suggesting workflow imbalance.
Scheduling Fix: Implement level loading to smooth out peaks and valleys, improving overall efficiency by 15-20%.