Manufacturing KPI Library
Every metric that belongs on a plant scorecard: what it means, how to calculate it, what good looks like, and the DAX to build it in Power BI.
Labor
- Absenteeism Rate · Unplanned absence hours ÷ total scheduled hours
- Labor Productivity · Units produced ÷ total labor hours
- Overtime Percentage · Overtime hours ÷ total hours worked
Quality
- First Pass Yield (FPY) · Units passing a process step correctly on the first attempt ÷ total units started
- Scrap Rate · Scrap units (or scrap cost) ÷ total units produced (or total cost)
- Defect PPM (Parts Per Million) · (Defective units ÷ total units produced) × 1,000,000
Financial
- 4-Wall Margin · (Plant revenue - plant-controllable costs) ÷ plant revenue
Production
- OEE (Overall Equipment Effectiveness) · Availability × Performance × Quality
- Schedule Attainment · Units produced ÷ units scheduled (per line, per week)
- Takt Time · Available production time ÷ customer demand
- Unplanned Downtime % · Unplanned downtime minutes ÷ total planned production minutes
- Changeover Time (SMED) · Time from last good unit of the previous run to first good unit of the next run
- Cycle Time · Run time ÷ units produced
- MTBF (Mean Time Between Failures) · Total operating time ÷ number of failures
- Capacity Utilization · Actual output ÷ maximum practical capacity
- MTTR (Mean Time To Repair) · Total repair time ÷ number of repairs
Delivery
- On-Time Delivery (OTD) · Orders delivered on or before the promised date ÷ total orders shipped
- OTIF (On Time In Full) · Orders delivered on time AND at full ordered quantity ÷ total orders
- Past-Due Backlog · Count (or $ value) of open orders past their promised date
Inventory
- Inventory Turns · Cost of goods sold ÷ average inventory value
- Inventory Days on Hand · (Average inventory value ÷ COGS) × 365
Safety
- TRIR (Total Recordable Incident Rate) · Recordable incidents × 200,000 ÷ total hours worked