Manufacturing Downtime Analysis

Executive Summary

Between days Aug 29 – Sep 3, 2024, soda manufacturing operations experienced 1,388 minutes of downtime — primarily caused by operator errors during afternoon shifts. This reduced batch success by 35.6%, and decrease production by at least 14 batches.

By addressing top issues (CO-600 product faults and operator inefficiencies), line efficiency could improve from 64% to an estimated 76%, allowing the production of at least 8 additional batches. The following section will provide a runthrough on what happened to the operation and how it affects the company.

Key Insights

  • 1
    Production shows inconsistent line efficiency

    Underutilization of production time across the team.

  • 2
    Afternoon shifts records the most downtime occurrences

    13:00 PM to 22:00 PM (1PM to 10PM) workload needs realignment.

  • 3
    CO-600 downtime almost doubled that of the other two products

    Production of CO-600 was revealed as the most issue prone product.

Dashboard Overview

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  • Production shows inconsistent line efficiency

    Operator Error accounts for 56% of downtime, indicating underutilization of production time across the team. Even the top performer, Charlie, lost 384 minutes (30% of production time) — equivalent to 4 lost batches. This suggests the need for refined standard operating procedures and training to help all operators work more consistently and efficiently and increase line efficiency closer to the target of 70%.

  • Afternoon shifts records the most downtime occurrences

    It is recommended to realign the 13:00 PM to 22:00 PM workload. Operator Error again is the leading issue on this shift, and if able to reduce the downtime by 50% it would lead for at least 4 more batches.

  • CO-600 downtime almost doubled that of the other two products

    Strongly recommended to reassess the production of C0-600 as it alarmingly takes up almost half of the downtime minutes. Machine error records the highest issue on its production which is an implication for the need to recheck machine readiness and overall C0-600 production process. If addressed this would reduce cost of about 8 batches.

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