IIntroduction: Preventing Friction Fires on the Line
- Hook: Every production line encounters friction, from an underperforming machine to an untrained operator. When one segment slows, the entire system suffers.
- Problem: Without accurate visibility into production metrics, small capacity variances compound quickly, leading to delayed orders, missed targets, and margin erosion before anyone realizes there’s a problem.
- Solution Overview: DPS provides the tool kit and structure for the frontline to track production performance across every line and shift, surfacing early warning signs when output falls off plan.
- Thesis: DPS gives frontline leaders instant visibility into operational issues or lost time — allowing them to act, not react — and reinforces accountability through ownership of the data, short-interval follow-ups, corrective measures, and outcomes.
IICapacity Tracking: The First Signal of Trouble
- Function: DPS dashboards visualize capacity utilization (plan vs. actual) by product, shift, area, line, supervisor, date range, and day, highlighting deviations quickly.
- Key Tools:
- Daily Schedule Control: Track hourly production performance with short interval follow up.
- Lost Production Tracker: View all Lost Production Events like waste, rework, and holds, and evaluate the top causes.
- Skills Flexibility Matrix: Manage worker skills and proficiency levels across production areas.
- Downtime Tracker: View all downtime events and evaluate the top causes.
- Action Items Log: Assign and track progress of continuous improvement efforts.
- Mission-Critical Metrics:
- Capacity Utilization
- Startup Score %
- Total Units
- Downtime %
- Uptime %
- Units/Labor Hour
- In Practice: When first-hour of production attainment dips (e.g., 60%), it can be flagged in DPS and set to prompt leaders to investigate, reallocate, or escalate through mobile alerts.
- Value: DPS helps turn raw production data into actionable insight, letting teams see where and why capacity slips before it spreads.
IIIShort-Interval Follow-Ups: From Data to Rapid Root Cause Correction
- Trigger: Every capacity deviation can be logged in DPS for short-interval review — while the data is fresh and the issue still recoverable.
- Integration with the Floor: Downtime and lost production events help give insight and data into uncovering the root cause.
- Common Root-Cause Categories:
- Equipment: Mechanical slowdowns or missed PM tasks.
- Labor: Untrained fill-ins or attendance gaps.
- Inputs: Material shortages or misaligned delivery timing.
- Impact: These short interval follow ups reduce resolution time compared to daily huddles, ensuring production stays on plan.
IVShort-Interval Follow-Ups: From Data to Rapid Root Cause Correction
- Beyond Alerts: DPS doesn’t just surface problems, it embeds accountability through ownership of the data and the corrective actions.
- Supporting Features:
- Direct Messaging: Enables instant communication to align operators, maintenance, and frontline supervisors.
- Company Knowledge Hub: offers a centralized platform for sharing important announcements, files, and notifications—keeping everyone in the loop and fostering a culture of collaboration.
- Cultural Benefit: Leaders build credibility by acting visibly on data, while teams see their contributions directly improving results. The result: stronger alignment and disciplined follow-through.
VImplementation Roadmap: Embedding DPS for Capacity-Driven Control
- System Configuration: Implement site configurations for shifts, areas, and lines. Load equipment assets, downtime categories, and reasons. Load lost production categories and reasons. Create custom Startup Scorecard criteria by area.
- Data Collection: Initiate data gathering from the Startup Scorecard and Daily Schedule Control via short-interval follow-up routines.
- Short-Interval Follow-Up: Perform hourly reviews of Plan vs Actual and performance to uncover operational realities and pinpoint emerging performance gaps.
- Performance Review: Convene the team off the production floor for daily or weekly meetings to evaluate performance. Analyze Downtime Paretos, Lost Production Paretos, and Startup Paretos to identify the most promising opportunities.
- Corrective Actions: Prioritize root cause analysis, action items, and Kaizen events on the highest-impact opportunities surfaced by frontline leaders from the collected data.
- Continuous Improvement: Assess the impact of corrective actions, standardize and refine processes, and conduct training to solidify these practices for enduring results.
- Outcome: Quick wins through immediate recovery of lost hours, followed by sustained gains through repeatable routines and shared insights.
VIConclusion: Fire Prevention – Win Every Shift with DPS
- Recap: Bottlenecks are inevitable — but downtime disasters aren’t. DPS turns production data into an early warning system that empowers leaders to detect, diagnose, and correct issues before they stall the line.
- Call to Action: Ready to see how DPS flags friction point before it becomes a failure point, request a demo today.
- Closing Thought: With visibility and accountability, DPS helps you win every shift — not by chance, but by design.