Category Archives: KPI

Key Performance Indicator – or KPI – are measurements regarding different shop floor performances.

The Many Different Flavors of the OEE

OEE flavorsIf imitation is the sincerest form of flattery, the OEE (Overall Equipment Effectiveness or Efficiency) is indeed one of the most appreciated measures in lean. I counted at least eight different variants and adaptions of the basic OEE – although let me tell you that I am not impressed with all of them. Many of them seem to be theoretical academic constructs with little meaning for your shop floor. Also, identical acronyms and similar terms are often used in a completely different way, adding quite a bit to the confusion. On top of that, I think the OEE is used way too much in industry where it does not make sense, and many OEE numbers are heavily fudged. Anyway, let me show you the many different flavors of the OEE. Continue reading The Many Different Flavors of the OEE

Good and Bad Ways to Calculate the OEE

Smiley Frowney PercentThere are different ways to calculate an OEE. I know of at least three different ways. However, some of them are easier and more practical than others.

Maybe you have seen a formula similar to OEE = A x P x Q. I see this formula often, but for me it is a very impractical way to calculate the OEE. Let me show you why by comparing the three different ways to calculate an OEE.  Continue reading Good and Bad Ways to Calculate the OEE

The A3 Report – Part 3: Limitations and Common Mistakes

A3 on ClipboardIn the last two posts I showed you the basics of the A3 report and the (possible) content of the A3 report. In this last post of this series, I would like to talk about common mistakes and the limitations of the A3 report. Overall, for me the A3 report is a minor tool to help organize the real work of problem solving, despite all the fuzz some make about the A3 report. Continue reading The A3 Report – Part 3: Limitations and Common Mistakes

The A3 Report – Part 2: Content

Handwritten A3 report
An A3 visualization in pencil

In my last post I wrote about four basic factors for an A3 report (one sheet / A3 size / with pencil / on the shop floor). This week I would like to show you what goes in an A3 report. The important framework here is PDCA (Plan, Do, Check, Act). However, in my view there is no single perfect A3 template that will fit all of your problems. Rather, an A3 is created on the go. Make the tool fit the problem, not the other way round! Continue reading The A3 Report – Part 2: Content

The A3 Report – Part 1: Basics

DIN A Paper SizesIf you know your way around lean, you surely have hear about the A3 report, famously named after the DIN-A3 paper size. It is also known as the A3 problem-solving sheet. The goal is to get all the  necessary data on one sheet of A3 paper using pencil while you are on the shop floor. The A3 report is commonly used for problem solving, but also for project management or status reports. Continue reading The A3 Report – Part 1: Basics

What Is Your Production Capacity?

Three HourglassesYour production capacity is one important aspect of your production system. The capacity has to match your demand. If your demand is higher than your capacity, then you will not be able to supply the customer. On the other hand, if your capacity is higher than the demand, then you will have lots of idle workers and machines, which is not good either. The name is actually a bit of a misnomer, since capacity is the ability to contain  things, whereas for a production system we are much more interested in the number of parts that are completed. In any case, capacity is important! Continue reading What Is Your Production Capacity?

Lies, Damned Lies, and KPI – Part 3 Countermeasures

Kid with Glasses
How to measure good KPIs

There is an inflation of key performance indicators (KPIs) in industry. In my last posts I have explained how KPIs are often wrong, and why bad and fudged KPIs are a huge waste. Yet, you cannot really run a larger corporation without KPI. In this post I will finally give some advice on (1) what you need to do to measure good KPI, and (2) how to avoid fudged KPI. Continue reading Lies, Damned Lies, and KPI – Part 3 Countermeasures

Lies, Damned Lies, and KPI – Part 2: Effects of Fudging

Business fraud
About the ills of number fudging

Modern manufacturing works with a lot of performance measures, often called key performance indicators (KPIs). Unfortunately, they are rarely accurate, and often even intentionally misleading. In my previous post I described some examples of commonly manipulated KPIs. In this post I would like to explain the ugly consequences of incorrect or manipulated KPIs. In a final post I will also show some ways that you can reduce this negative effect. But first, how do bad KPIs (and hence most KPIs) hurt your company? Continue reading Lies, Damned Lies, and KPI – Part 2: Effects of Fudging