Any manufacturing organization can monitor its results as per the following formula. Manufacturing industries day to day activities in Management , Production, Quality, Cost, Delivery, Safety and hygiene, Education and morale.
Overall Management
Sales
Actual values
Recurring income
Operating Income + nonoperating income - nonoperating expenses
The ratio of net income to total capital
(income (before taxes) / total capital ) X 100
Added value productivity
Annual added value / no of employees
Fixed asset turnover ratio
(Net sales / Fixed assets)
This indicator shows the degree of usage of fixed assets; the higher this rate is, the more sufficiently equipment and facilities are utilized
No of new products and technology development
Actuals
Ratio of profit to net worth
(Annual net profit / period sales) X 100
Annual per-capita net profit
(Annual net profit / no of employees) X 100
Net income to sales
Net profit / period sales X 100
Profit Innovation ratio
(sales of products developed within the past three years / sales of total products) X 100
Production
Productivity
Production expenses (Production Value) / No of workers (Total work hours)
Output Volume per unit of labor
Overall Equipment Efficiency
Availability X Performance rate X Quality products rate
Degree of contributions of current equipment and facilities to product-yielding time, viewed aggregately from time, speed, and Quality aspects.
Availability
(Loading time-Downtime)/Loading Time
The ratio of operating time to loading time excluding equipment downtime (failures, setup, and adjustment)
Performance Rate
(Output X Actual cycle time) / (Loading - Downtime) X (Standard cycle time / Actual cycle time)
Indicators to calculate speed losses; calculation of speed losses that are not indicated in the time utilization ratio
Quality products rate
( (No. of input parts - No of defective parts) / No of input parts )
No of failures
Actual values
No. of sporadic failures
Failure duration rate
(Total Failure downtime / Total loading time ) X 100
the ratio of time when equipment stopped due to failures
Failure frequency rate
(No of downtime / total loading time ) X 100
Rate of failure occurrence per loading time
MTBF (Mean time between Failures )
(Total Operating time / no of downtime)
Average operation time between failures
MTTR
Total repair time / no of repair
Average repair time
Setup time
Actual Values
No of Minor stoppage
Actual Values
Labor equipment ratio
(Machinery and equipment + tool and fixtures + vehicles and transport equipment) / No of Employees
Capital Investment efficiency
(total processing amount/equipment assets ) X 100
Rate of equipment assets in total processing amount; an indicator of capital productivity
Planned Maintenance achievement ratio
( No. of implementation cases / no of planned maintenance cases ) X 100
Preventive maintenance rate
((PM expenses + CM expenses) / (PM expenses + CM expenses + BM expenses) X 100
Automation rate
( No. of automated elemental work / total no of elemental work ) X 100
The rate of automated elemental tasks in total elemental work in equipment and lines, elemental work represents five items: mounting, processing, quality checking, dismounting and transport of products
Shifting to unattended operation
Residual ratio during nighttime / daytime operation
Rework
Yield
Quality
In-process defects
Actual values
No of complaints
Actual values
Rate of returns of already delivered products
(No of returns of already delivered units / no of delivered units ) X 1000000 (PPM)
Quality evaluation
Quality break-even point - (Inspection cost per unit of product/losses arising from one defective unit)
Amount of market complaints
Actual values
Cost
Streamlining expenses
Actual values
Maintenance expenses
Actual values
Capital turnover
Net sales / fixed assets
An indicator of the degree of fixed asset utilization; the higher this turnover, the more equipment assets are utilized
Amount of disposal of fixed assets
Depreciation ratio
(Depreciation cost / fixed assets ) X 100
Delivery
No of delayed days
Actual delivery date- promised delivery date
No of days product is retained
Average product backlog/ average monthly sales
Safety and hygiene
Accident frequency rate
(no of accidents resulting in workdays lost / work hours ) X 1000000
An indicator of the frequency of accident occurrence; no of cases in 1 million work hours
Accident duration rate
(no of labor loss days / total work hours) X 100 h
An indicator of the degree of accidents; ratio of workdays lost to a total of 100 work hours
Education and morale
Circle activity hours
Actual values
No of circle activity meetings
Actual values
No of improvement proposals
Actual values
No of external presentations
Actual values
Qualifications/certification
Actual values
No of erroneous operation
Actual values
No of trainees
Actual values
Time to pick up necessary documents
Actual values
Autonomous Maintenance rate
(No of operator fixing cases / total no of failures) X 100
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