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OperationalRatio (OPR)Alain Prioul2007June
OPR measures the Gap’s adherence toparts boards’ targetsPC&LParts Boards’targetsGAPPDPLevelingBoardFCA Internal MPMPRODUCTION:OPR achievement of requestedquantityPlant MPMPC&L:PDP Steering /Monitoring2
PDP’s achievementKEY ASSUMPTION: the daily / by shift quantities in PDPhave to be achieved, whatever unplanned losses occur.There are 2 main ways to make it:1st1st waywayFaurecia Standard is to compensate losses by overtime at end of shiftnd way,22ndway, whenwhen overtimeovertime isis notnot possiblepossible atat endend ofof shiftshiftz Production Cycle Time must be faster than Takt Time to absorb the difference:Production Cycle Time Target Cycle Timez Targets in Parts Board higher than PDP.AlternativeAlternative wayswaysz Work during breaksz Gap leaders compensation for losses.3
Definitions: TT, TCT, OPRTT TCT OPR Opening Time – Planned stopsDaily requirementsOpening Time – Planned stops – usual additional lossesDaily requirements scrapsActual OutputParts Boards requirementsWithin normal operating hours(without overtime)FAURECIA Objective: TCT TT4
Target Cycle Time (TCT)HolidaysAbsenteeism paidMedical careWork CouncilClassroom TrainingLunch BreakLong leave absenceUnion meetingsExplanationsfor lossesmustappear onthe partsboardshour afterhourPLANNED STOPS:Top 5Paid breaksPlanned ChangeoversPaidHoursCleaning Time*Preventive Maintenance**Time spenton theshopfloorTimeplanned forProductionbased onTakt TimesLOSSES/HAZARDS:ScrapsMachine BreakdownsChange over standardsEfficient timeBased untby MgtdecisionTime used tocalculateParts BoardsTarget CycleTimes*: should not exist **: should be outside of working hours 5
OPRz The ability of the Production line to reach the goal hasto be measured by shift.z Ideally, the OPR should be between 95% and 98%.This is a target, and we will start from where we are.z If OPR is regularly above 98%, targets and resourcesmust be reconsidered.z If target is never achieved, meaning not feasible, wealso need to reconsider targets or/and resources.6
OPR and parts boards’ targetsOVERTIME POSSIBLE OVERTIME NOT POSSIBLETARGETS INPARTS BOARDSTARGETS PDPTIMETTLOSSESCOMPENSATEDBY OVERTIMEOPRACTUAL (before overtime)TARGETS ( PDP)TARGETS PDPTCTCOMPENSATEDBY HIGHER TARGETS &RESOURCESACTUAL (before overtime)TARGETS ( PDP)7
OPR, PPH, TRSz OPR measures ability to reach planned quantities in thetime scheduled, and does not measure productivity.PC&Lis in charge of the follow up.z Manpower productivity is measured by PPH.z TRS measures equipment usage on a 24 hours basis.8
Example of Parts Board with overtimepossible (TT 60s)Target PDPHour 1Hour 2Hour 3TOP 5 (55 x 60)/60532 scraps60 (60 x 60)/60564 minutes machine breakdown (50x60)/6050 (60x60)/6058 (50x60)/6050 (60x60)/6060 (50x60)/6050 (50x60)/60428 minutes machine breakdown419We do not deliver customerdemand (or PDP).So we must produce 16parts more with OT rightway at end of this shift !BREAK 10 Minutes5060Hour 5MAINTENANCE5060Hour 7BREAK 10 minutesHour 8CLEANING 10 minutesTOTALOPROvertimeExplanations55Hour 4Hour 6Targets’Actualcalculation (nb of parts)5050435 96.3% 419/43516 minutes162 scraps9
Example of Parts Board without overtime(TT 60s, TCT 58s: 16 minutes in 8 hours or 2 s every 60s)Target PDPHour 1Hour 2Hour 3TOP 5 (55 x 60)/58552 scraps62 (60 x 60)/58584 minutes machine breakdown (50x60)/5852 (60x60)/5860 (50x60)/5852 (60x60)/5862 (50x60)/5852 (50x60)/58448 minutes machine breakdown435We do not achieve Partsboard targets but we deliverthe customer demand (orPDP). OT not needed !But we have to improve inorder to get OPR 98%10stabilized.BREAK 10 Minutes5262Hour 5MAINTENANCE5262Hour 7BREAK 10 minutesHour 8CLEANING 10 minutesTOTALOPRExplanations57Hour 4Hour 6Targets’Actualcalculation (nb of parts)5252451 96.4% 435/4512 scraps
3 PDP's achievement Faurecia Standard is to compensate losses by overtime at end of shift zProduction Cycle Time must be faster than Takt Time to absorb the difference: Production Cycle Time Target Cycle Time zTargets in Parts Board higher than PDP. 22ndndway, when overtime is noway, when overtime is not possible at end of shiftt possible at end of shift
