Shift Handoff
This project was a BI report developed to visually display daily production targets and measure progress of each department and work center within manufacturing throughout the workday.
Background: Originally, this BI report was designed as a handoff report to help communicate and strategize work priorities between shifts. This report would show 2nd shift knew where work had already been completed during 1st shift, and where to focus labor efforts to assist the department in meeting the daily goals. This report was a big improvement for operations because it visually displayed what had been done throughout the day and it provided a standard way of calculating production targets that automatically recalculated if the scheduled changed with a long enough range to level out any schedule variability. Since the report updates earned hours every 30 minutes throughout the day, this BI report quickly became used throughout the entire day to measure and adjust production labor to meet daily goals even within the shift. Today, it is the most accessed BI Report at Piper Aircraft each day.
Visual Management: The colored bars on the right of the report are a great visual indicator of progress throughout the day. If a department’s earned hours are below 100% of the daily target hours the bar is red, if a department’s earned hours are between 100% and 200% of the daily target hours the bar is green. The over 200% production color was included because it is just as much of a concern as being under 100%. In an ideal situation, if caught up, once a department, machine, or work center has met their daily target hours, those resources could and should be flexed to assist other areas and reduce over production.
Report Logic:
Daily Target Hours: This value is calculated using an ERP table of orders and operations planned in the future and is calculated by summing the total standard hours of the operations due 21 - 180 days from today’s date divided by the number of working days between 21 - 180 days from today’s date. This represents an average daily target hours.
Daily Target Operations: This value is calculated using an ERP table of orders and operations planned in the future and is calculated by counting the total number of the operations due 21 - 180 days from today’s date divided by the number of working days between 21 - 180 days from today’s date. This represents an average daily target operations.
Backlog Hours: This represents the total standard hours of work orders that are in backlog. This is the same as behind schedule hours, late hours, past due hours, etc. due before today’s date.
Days Behind: This value is calculated by dividing the backlog hours by the daily target hours to get a representation of the number of days behind a department is.
% Complete: This value is calculated by dividing the number of hour’s earned today by the daily target hours to measure daily progress.
Drilling in/Hyperlinks: Users can drill into a department by clicking on the department number to view the same format of information, but at a detailed inner-department level showing machines/work centers within that department. Users can also drill into the backlog hours for more details from other BI reports. Lastly, users can also switch to a weekly view where the daily targets are multiplied by 5 (5 days in a week), the days behind becomes weeks behind, and the earned hours is the sum of hours earned since Monday of the current week.
This project was developed using Cyberscience’s ECQ BI reporting software.
