Data protection noticeThis tool records production output, which can reveal how a team or shift performed. It stays in this browser and in files you save. Nothing is sent to this website. Name lines or cells, not people. Do not use it to rank individuals, and do not record who was absent or why. Only use the tool with your employer's approval, on a company device, and save files only to your company's approved location. Clear data from this browser when you have finished.
Planned and actual by day
PlannedActual
Units short, by reason
Units shortCumulative share
By line
What the checks found
The checks look for gaps in the record: blocks with no plan or no actual, misses with no reason, duplicates and dates in the future. They cannot tell whether the plan was a fair one or the counts are true.
What it measures
- A block is one planned period for one line: an hour, a shift or a day. Use the same size of block for a line. Do not record both a day total and the hours inside it.
- Blocks on plan is the share of blocks where actual met plan, within the tolerance you set. This is the main measure, because it cannot be hidden by one good block covering a bad one.
- Attainment is total actual divided by total planned, for blocks that have both. It can look healthy when overbuild covers a shortfall, so read it beside blocks on plan.
- Units short adds up the shortfall on every missed block. Units over adds up the overbuild. They are not netted off.
The rules the log applies
- A block with no plan, or a plan of zero, cannot be judged and is flagged.
- A past block with no actual recorded is a gap. It is left out of the results and counted separately, never treated as met.
- A missed block needs a reason, taken from the same list as the OEE and Downtime Log. "Other" needs a note.
- Building well over plan is noted. It is waste, and it can mean the plan was wrong.
- Results are added up only within one unit, so cars are never added to parts.
- If most misses are put down to "plan changed", the original plan is being rewritten. Record the plan as it stood at the start of the block.
Reading the charts
The Pareto ranks the reasons by units short. Work on the top one or two first. Reasons are only as good as the people recording them, so check a few against what the line was doing, and see the OEE and Downtime Log for the stop times behind them.
Related tools
Misses that repeat belong on the Daily Management Board. Work a cause through on an A3 sheet or with the 5 Whys Tool.
Limits
No gaps found does not mean the plan was right or the counts are true. This is decision support only.