Implementing Day-by-Hour Production Tracking Boards

Twitter

Implementing Day-by-Hour Production Tracking Boards

As a lean transformation consultant, I work on improvement projects with manufacturing clients. Many of these clients use visual management tools such as Daily Management Boards which are used to track Safety, Quality, Delivery, Cost and People metrics to track daily production performance. The problem with these metrics is they are not tracking real-time performance data.

I am often asked, “what is the best technique for tracking production output in real-time?”

My answer is to implement a Day-by-Hour, also known as Hour-by-Hour boards into the production areas. These types of boards are used to track production output in real-time, identify issues quickly, and maintain focus on meeting production targets.

Ideally, production forecasting and planning requires capacity analysis to determine the achievable workload for each production process. To generate an accurate production schedule using capacity analysis requires the availability of accurate cycle times for products. Sadly, not all clients will have accurate or updated standard cycle times available.

Let’s explore three different scenarios for implementing Day-by-Hour or Hour-by-Hour boards into production cells in a manufacturing facility:

  1. A facility that has standard times available with a Low-Mix and High-Volume (LMHV) production schedule.
  2. A facility that has standard times available with a High-Mix and Low-Volume (HMLV) production schedule.
  3. A facility that does not have standard times available with either a High-Volume and Low-Mix (LMHV) or a High-Mix and Low-Volume (HMLV) production schedule.

Scenario 1 - Low Mix, High Volume Production

Characteristics

  • Few product variants
  • High production volumes
  • Standardized processes
  • Consistent cycle times
  • Predictable demand patterns
  • Regular production schedules

Implementation Approach:

In LMHV environments, Day-by-Hour boards should focus on pure quantity tracking against established targets.

The implementation should include:

  1. Fixed Hourly Targets
    • Set consistent hourly production goals
    • Base targets on takt time calculations
    • Account for planned breaks and changeovers
  2. Simple Visual Tracking
    • Use clear numerical targets
    • Track actual production hourly
    • Calculate and display variances
    • Use color coding (green/red) for instant visual feedback
  3. Standardized Problem Codes
    • Limited set of common issues
    • Focus on equipment-related problems
    • Track changeover times
    • Monitor quality issues

Example LMHV Day by Hour Board Layout:


Scenario 2 - High Mix, Low Volume Production

Characteristics

  • Multiple product variants
  • Multiple setup and changeovers
  • Small batch sizes
  • Variable processes
  • Fluctuating cycle times
  • Custom orders
  • Flexible production scheduling

Implementation Approach:

HMLV environments require a more sophisticated approach to implementing Day-by-Hour boards, focusing on both quantity and product mix.

The implementation should include:

  1. Flexible Targeting
    • Variable hourly goals based on product mix
    • Weighted targets accounting for different cycle times
    • Dynamic adjustment capability
  2. Detailed Production Tracking
    • Track multiple products simultaneously
    • Monitor setup and changeover times
    • Record product-specific issues
    • Track order completion status
  3. Comprehensive Problem Coding
    • Expanded set of problem codes
    • Product-specific issues
    • Setup and programming delays
    • Customer specification related delays

Example HMLV Day by Hour Board Layout:


Scenario 3 – Implementing Day-by-Hour Boards Without Established Cycle Times

In this scenario, whether it be a LMHV or HMLV production facility, there needs to be a phased approach to implementing any Day-by-Hour boards.

Phase 1: Initial Data Collection (Weeks 1-2)

Step 1: Baseline Observation Period

  • Use the day by hour board as a pure data collection tool initially
  • Focus on recording actual production times without setting targets
  • Document all variables affecting cycle time
  • Track natural production patterns

Example Collection Board Layout (Initial Phase):


Phase 2: Initial Target Setting (Weeks 3-4)

Step 1: Calculate Preliminary Targets

  • Use the 80th percentile of observed times as initial baseline
  • Add 15% buffer for variability
  • Create ranges rather than fixed numbers
  • Document assumptions

Example Target Setting Board:


Phase 3: Implementation with Built-in Refinement (Ongoing)

Step 1: Modified Day by Hour Board:


Key Success Factors:

  1. Operator Engagement
    • Involve operators in data collection
    • Encourage detailed notes on variations
    • Create feedback loops for continuous improvement
  2. Regular Review Process
    • Daily review of actual vs. range performance
    • Weekly adjustment of ranges based on data
    • Monthly analysis of patterns and trends
  3. Progressive Refinement
    • Start with wider ranges
    • Narrow ranges as consistency improves
    • Document factors affecting variation
  4. Documentation Requirements
    • Record all assumptions
    • Track external factors
    • Note special circumstances

Common Pitfalls to Avoid

  1. Setting targets too early
  2. Making ranges too narrow
  3. Ignoring operator input
  4. Failing to document variations
  5. Not adjusting for learning curves

Tips for Success

  1. Start Simple
    • Begin with major product families
    • Use broader time ranges initially
    • Focus on consistent data collection
  2. Build Confidence
    • Validate data with operators
    • Celebrate accuracy improvements
    • Use data to drive improvements
  3. Maintain Flexibility
    • Allow for adjustment periods
    • Account for seasonal variations
    • Consider equipment variations
  4. Document Everything
    • Keep detailed records
    • Track improvement initiatives
    • Monitor impact of changes

Progression Timeline

Week 1-2: Pure data collection

Week 3-4: Initial range setting

Week 5-8: Range refinement

Week 9+: Continuous improvement

Remember: The goal is to establish reliable cycle times while maintaining production visibility. It's better to have rough targets that are consistently achievable than precise targets that don't reflect reality.

Categories: : Training

© 2025 radical-transformation