Production planning and shop-floor reporting for a global auto-components manufacturer
Manufacturing
The challenge
Three shops, twenty-one lines and four shift windows a day were planned and reported in spreadsheets — so the same shift was typed several times over, and the month-end numbers could not be traced back to the machine that produced them.
What we built
We built a single Daily Production Log: one screen, per line and per shift, where actual production, lost minutes, manpower and rejections are entered once. Every report the plant already ran is generated from it — including the spreadsheet exports, rebuilt to match the formats the shop floor had been signing for years.
The result
Twelve reports now come out of one entry screen. OEE is calculated per line from the same data rather than assembled by hand at month end. A signed report is frozen and cannot be altered by a later change to a cycle time or a plan.