Waterfall KPI Reporting System

Global Waterfall

Definitions
 Time

1.
Theoretical hours

2.
Legal non operating time

No demand

3.
Line Utilization

Hours used

4.
Global Waterfall Model

Major maintenance, Major sanitation

5.
6.
Maintenance

Changeovers

7.
Sanitation

8.

2
9.
Break and test

Planned line activities

Global Efficiency

10. Production Hours

Equipment delays
11.

Material & labor delay

12.

Speed Losses
13.

Defect Losses
14.
Unplanned Shutdown

Defect free, full speed

15.

operating time
Overall Equipment Effectiveness
 Line Utilization of a production line

Hours used (including efficiency losses)

Theoretical Maximum Available Hours (24/7/52)

• Hour Used = Theoretical Hours – (No

Demand + Legal Holidays)
• Theoretical Hours = 24 hours/day = 168
hour/week = 8,760 hour/per year
• Line Utilization (LU) measures the
effectiveness of how a line is used
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 Global Line Efficiency
Full Speed Defect Free Operating Time (Hours)
Hours Used (Hours)

• Full Speed Defect Free Operating time

– Full Speed = Maximum speed attainable by the Bottleneck
– Defect Free = Saleable Product transferred to the next process
– Operating Time = Refers to amount of time production ran at Full
Speed and produced Defect Free product
• Global Efficiency (GE)
– Measurement of asset capacity utilization calculated as a ratio of the
actual product produced to the theoretically possible amount of product
that could be produced during the theoretical hours minus the No
Demand and Legal Holiday hours.

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Overall Equipment Effectiveness (OEE)
Full Speed Defect Free Operating Time (Hours)
Production hours
• Full Speed Defect Free Operating time
– Full Speed = Maximum speed attainable by the Bottleneck
– Defect Free = Saleable Product transferred to the next process
– Operating Time = In this case refers to time production ran at Full
Speed and produced Defect Free product
• Production Hours
– Hours remaining after subtracting Legal Holidays, No Demand, and
Planned Events from the Theoretical Hours
• OEE is a measurement of equipment or conversion process
efficiency, and is the ratio of Full Speed Defect Free
Operating Time to the Production Hours.
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Overall Equipment Effectiveness (OEE)
OEE = Availability x Performance x Quality
• Availability
– Equipment Delays – Breakdowns
– Minor Stops
• Performance
– Material and Labor shortages
– Idle Time
– Reduced Speed Operation
• Quality
– Rejects & Rework
– Scrap
– Holds

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1. Theoretical Hours

• Total number of hours

making up the selected date
range.
• 168 hours per week
Legal non operating time

• 8,760 hours per year (8,784

Theoretical hours

during Leap Year)

Hours used
No demand

1. 2. 3. 4.
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 2. Legal Non-Operating Hours
• Days not allowed to work due to governmental
regulations or contracts
- may include certain official country bank or union
contract holidays.
- can be line or product specific
• General strikes
• Catastrophes outside of the company e.g. float,
epidemic…
Legal non operating time

• Does not include:

Theoretical hours

– Plant holidays (Included in No Demand)

– Week-end or Sunday
Hours used
No demand

– Plant shut down due to capacity reason

– Approved legally working exceptions
– No demand situations
1. 2. 3. 4.
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 3. No Demand
• Hours not scheduled for production or
related activities due to lack of demand
• Includes:
– Plant holidays
– Days off
– Week-end or Sunday
– Plant shut down due to capacity reason
Legal non operating time

– Approved legally working exceptions

– No demand situations
Theoretical hours

Hours used
No demand

1. 2. 3. 4.
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 4. Hours Used

• Total Time Available for

Production:
• Hours Used = Theoretical
Hours – Legal Holidays –
Legal non operating time

No Demand
Theoretical hours

Hours used
No demand

1. 2. 3. 4.
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 5. Major Maintenance, Major Sanitation
• Major Maintenance
– Not related to Production Schedule
– Lasting more than 3 Shifts
• Major Sanitation
Major maintenance, Major

– Not Related to Production Schedule

– Lasting more than 3 Shifts
• Does not include:
Break and test
Maintenance

Changeovers
Hours used

– The shift cleaning /weekend cleaning

Sanitation
Sanitation

related to production
– Daily routine tasks which occur
4. 5. 6. 7. 8. 9. during Production Hours

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 6. Maintenance
• Maintenance
– Preventative Maintenance lasting 3 shifts
or less
– Planned Maintenance occurring during
Major maintenance, Major

Production Hours
– Corrective maintenance occurring after
the production schedule is closed.
Break and test
Maintenance

Changeovers
Hours used

Sanitation
Sanitation

NOTE:
For parallel activities such as Change-Over,
Cleaning, and/or Maintenance, Change-over has
the highest priority (to display complexity). All
4. 5. 6. 7. 8. 9.
activities exceeding will be reported at their
specific activity.

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 7. Changeovers

• Changeover time from SKU to

SKU
• The time from the last case of
the prior product to the first case
Major maintenance, Major

of the next product produced

Break and test
Maintenance

Changeovers
Hours used

Sanitation
Sanitation

NOTE:
For parallel activities with Change-over,
Cleaning, and/or Maintenance, Change-over
has the highest priority (to display complexity).
4. 5. 6. 7. 8. 9. All activities exceeding will be reported at their
specific activity.

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 8. Sanitation
• Sanitation lasting 3 shifts or less
• Cleaning time; includes all types of
cleaning between two products
– Cleaning parallel to changeover must be
considered under Changeover. Do not
double count.
Major maintenance, Major

– Cleaning due to maintenance must be

considered under maintenance. Do not
double count.
Break and test
Maintenance

Changeovers
Hours used

Sanitation
Sanitation

NOTE:
For parallel activities with Change-over,
Cleaning, and/or Maintenance, Change-over
4. 5. 6. 7. 8. 9. has the highest priority (to display complexity).
All activities exceeding will be reported at their
specific activity.
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 9. Break and Test
• Machine time scheduled for
breaks
– Lunch break, Team meetings, and
Training
– Tests (e.g. R&D) with total line
Major maintenance, Major

stopped or running non-saleable

product
• Does not include:
Break and test
Maintenance

Changeovers
Hours used

–
Sanitation

Machine breakdown
Sanitation

– Material shortages
– Labor delays
4. 5. 6. 7. 8. 9. – Other unplanned event

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 Production Hours

10.
Equipment delays

11.
Material & labor delay

12.
Speed Losses

13.
Defect Losses

14.
Defect free, full speed

15.
operating time
Overall Equipment Effectiveness
10. Production Hours

16
Hours run
• Actual Production
 11. Equipment Delay

• Lost time due to Choke

Overall Equipment Effectiveness Point being down
• Mechanical breakdowns
• Does not include:
Material & labor delay

Defect free, full speed

Production Hours

– Material Delays – neither

Equipment delays

operating time
Defect Losses
Speed Losses

raw or pack
– Labor delays
10. 11. 12. 13. 14. 15.

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 12. Material and Labor Delays

• Delays in raw or pack

Overall Equipment Effectiveness
material that shuts down the
Choke Point
– Shortage of Packing
Materials
Material & labor delay

Defect free, full speed

– Shortage of Raw Materials

Production Hours

Equipment delays

• Delays due to Labor

operating time
Defect Losses
Speed Losses

– Insufficient Labor
– Untrained Labor
10. 11. 12. 13. 14. 15.

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 13. Speed Loss

• Reduced speed operating

Overall Equipment Effectiveness time
– Time the line operated at
less than the maximum
Choke Point Speed
Material & labor delay

Defect free, full speed

• Calculated
Production Hours

Equipment delays

operating time
Defect Losses
Speed Losses

– (13) = 10 - (11 + 12 + 14 +15)

Comment: If negative speed losses

10. 11. 12. 13. 14. 15. occurs, maximum speed may have
been set incorrectly or shows
productivity
19 potential.
 14. Defect Loss

• Time where un-saleable

Overall Equipment Effectiveness
product was produced
– Also includes the losses due
to quality checks
Material & labor delay

Defect free, full speed

Production Hours

Equipment delays

operating time
Defect Losses
Speed Losses

Comment: Rework is Gross-

Rework and does include volume
of Rework (Finished Goods)
reused during production!
10. 11. 12. 13. 14. 15.

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 15. Defect Free, Full Speed Operating Time

• The equivalent time the

Overall Equipment Effectiveness
Line ran while producing
First Pass Quality product
at Maximum Choke Point
Speed
Material & labor delay

Defect free, full speed

Production Hours

• Product transferred from the

Equipment delays

operating time
Defect Losses
Speed Losses

line to the next operation

passing through the line
without rework
10. 11. 12. 13. 14. 15.

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