The production planning team is in charge of developing a production timeline and making sure that all requirements for manufacturing and production are met efficiently and cost-effectively.
Related: Production Planner, Production Supervisor, Production Assistant
- Employee Utilization Rate – The percentage of time during which a staff member is actively working versus the number of work hours expected for work (100% utilization means a staff member has no breaks)
- Takt Time – The optimal amount of time required to generate a single item, according to the total available work time and client demand (i.e. the speed of production required to satisfy demand).
- Projected vs. Actual Project Hours – The percentage of work conducted that were either unexpected (i.e., not scheduled) or did not comply with the production plan versus the total number of expected tasks
- Projected vs. Actual Project Hours – The percentage of the difference between hours planned for an employee versus the number of actual hours performed on the floor
- Production Division – A yes/no metric showing whether the firm has different departments devoted on a full-time basis to manufacturing and product assembly
- Product Cost – The average product value to the client at the company manufacturer as determined by the average cost per product unit and average gross margin
- Number of Production Employees – The total number of full-time equivalent (FTE) staff directly engaged in the production tasks of the firm being benchmarked
- Manufacturing & Assembly Groups – A yes/no metric showing whether the product manufacturing and assembly line FTEs are divided between two different groups
- The number of Stock Keeping Units (SKUs) – The total volume of SKUs generated by the firm across all manufacturing facilities.
- Dedicated Production Facilities – A yes/no metric showing whether the firm keeps production centers devoted to manufacturing specific items
- Inventory Turnover – A ratio that indicates how many instances a firm’s inventory is sold and refurbished over a determined time period, which can be measured by dividing the total sales by number of inventory or by dividing the value of products sold (COGS) by average number of inventory available during a specified selling period (monthly, quarterly, yearly)
- Manufacturing Site – Indicates the major factors used by the firm in assigning production across manufacturing centers: manpower costs, regulatory limitations. Distance to clients or suppliers, and others
- Percentage of Spare Manufacturing Capacity – The percentage of manufacturing power assigned by the company manufacturer as spare or excess capacity versus the total manufacturing power
- Capacity Utilization Rate – The percentage of the actual manufacturing yield versus the possible manufacturing yield
The manufacturing engineering office creates and improves systems such as software applications, procedures, and methods utilized in the manufacturing operation.
Related: Manufacturing Engineer, Manufacturing Process Engineer, Industrial Engineer
- Changeover Time – Calculates the total time it takes to shift a production plant from manufacturing a product to manufacturing a different one
- Manufacturing Uptime – The percentage of time that the manufacturing process is operative (creating products) versus the total available manufacturing time
- Mean Time to Repair – The typical amount of time (in minutes) needed to fix a damaged or broken piece of manufacturing machine
- Time to Convert Customized Solutions – The typical number of months needed to turn a custom-built solution into a regular product offering
- On-Time Delivery to Commit – The percentage of orders that manufacturing and production yields in full and on schedule versus the total number of orders fulfilled
- Customized to Standard Solution Offerings – A yes/no metric showing whether a manufacturer turns custom-built solutions into regular product offerings.
Manufacturing and Assembly
The manufacturing and assembly office is in charge of the construction of finished products.
Related: Manufacturing Technician/Operator, Assembler, Quality Assurance Inspector, Production Associate/Team Member
- Overall Equipment Effectiveness (OEE) – A calculation of the availability of the production facility (uptime), efficiency, and quality in one metric/KPI that evaluates the total efficiency of the whole production process
- First Pass Yield (FPY) – A measurement of the variance in items produced (output) by a production process versus the items that went into production (input) – i.e., input vs output
- Percentage of Units Reworked – The percentage of items manufactured that are modified for an upgrade or for correcting mistakes made during the manufacturing process versus the total number of items generated by the production team during a specified time period
- Scrap Rate Due to Errors – The percentage of items manufactured that must be disposed of due to product flaws or errors versus the total number of items generated by the production team during a specified time period
- Utilization Rate (Filling Line) – The percentage of the variance between actual and maximum yield being generated on an assembly line or production floor versus the maximum yield
- Labor Cost per Unit Produced (Unit Cost) – The total amount of labor cost needed during a time period divided by the number of well-produced during that period
- Percentage of Prefabricated Parts – The percentage of parts or components used in the manufacturing of a finished item that is pre-produced at a different location versus the total number of parts or components utilized
- Manufacturing Process Cycle Time – The typical number of days from the time the client’s order is received at the right manufacturing center until the merchandise is available for packaging for standard and custom-build merchandise
- Degree of Customization – The percentage of goods that are custom-built to particular customer requirement and need important modifications in the production process
- Dedicated Sub-Component Assembly Location – A yes/no metric showing whether the organization of particular sub-components happens at dedicated manufacturing plants
- Loss of Production Units – Percentage of the projected decline in production due to unexpected production interruptions during the preceding year versus the total planned production
- Production Attainment – Percentage of the production goals accomplished during a specified time period versus the total number of goals for that term
- Customer Lead Time – The average amount of time (in days) from the moment a client places a product order to delivery of the merchandise to the client
- Manufacturing Facility Productivity – Typical number of merchandise units produced every hour within the facility being benchmarked
- Non-Operating Time (NOT) Codes – The number of unique NOT codes utilized by the firm to describe reasons for manufacturing suspension
The facility management office is in charge of the regulation of the quality, safety, and cost of the properties utilized in the manufacturing process
Related: Facility Manager, Safety Manager, Maintenance Technician, Facility Technician, Maintenance Manager
- Manufacturing Site Considerations – A record of the major factors used by the firm in assigning production across production centers: manpower costs, regulatory limitations, distance to clients or suppliers, and others
- Work Organization “5S” Use – A yes/no metric showing whether the manufacturing team practice 5S (sort, straighten, shine, standardize, sustain) as a way to attain workplace coordination and efficiency
- Manufacturing Floor Space Usage – The percentage of the total available production floor space within the manufacturing area that is utilized for machinery, storage, organizing, etc., versus the total amount of available production floor space
- Safety Incidents per Employee – The number of registered safety-related incidents during a specified time period (month/week/year) divided by the total number of staff members working on the production area during that similar period
- Lean Production – A yes/no metric showing whether a manufacturer adopts lean production methods including timely delivery from suppliers and quality control circles
- Number of Manufacturing Sites – The total number of production centers maintained by the firm, local and overseas
Production Facility Manager Job Responsibilities
- Establishes mill schedules and directs plant personnel on a daily basis.
- Interviews and recommends associates for employment – Interviews and recommends associates for employment; conducts performance evaluations and salary reviews for assigned staff and is responsible for the application and enforcement of organizational policies including safety. Also, it monitors plant and equipment maintenance and repair.
- Monitors employee time cards.
- Monitor levels of raw materials and report shortages to Production Manager and Purchasing Supervisor.
- Oversees facility and equipment maintenance including negotiating with contractors, etc.
- Performs job according to pre-established safety, quality, and efficiency standard operating procedures.
- Performs job according to pre-established safety, quality, and efficiency standard operating.
- Responsible for duties of Production Manager in his/her absence.
- Reviews sales and production report to establish priorities for manufacturing.
Operations Manager Job Responsibilities
- Approve weekly hours as presented by Customer Service Mgr & forward to Bookkeeping
- Assist in any other area’s as necessary
- Assist in purchase of new equipment/trucks
- Assist in setting up of new equipment/trucks
- Attend one community networking function per month
- Commercial job bids
- Develop & emphasize best safety practices
- Ensure office & showroom are neat and clean at all times
- Field staff badging & credentialing
- Handle all customer complaints
- Handle IT troubleshooting
- Handle ordering of uniforms for new field staff
- Handle post install customer service telephone interviews
- Interview, hire and train new employees, or oversee those personnel processes
- Issue & maintain cell phone equipment for all staff
- Issue PO’s as necessary
- Maintain commercial safety accounts i.e. ISNetworld/Browz
- Maintain Home Depot/Clopay install account compliance
- Manage all disciplinary issues of subordinates
- Manage field issues as needed
- Manage staff, reviewing work schedules and assigning specific duties
- Manage technician productivity to meet company goals
- Oversee all activities related to field operations
- Oversee maintenance of building and grounds
- Oversee management of inventory control
- Oversee truck & equipment repairs
- Perform annual evaluations of direct subordinates
- Perform annual government Sam’s site registration
- Perform sales floor work, such as greetings or assisting customers, as needed
- Placement of all field staff job employment ads & Conduct preliminary duties
- Prepare and provide daily & weekly report to management as required
- Process field quotes for technicians
- Procure janitorial, yard & repair services as needed
- Randomly assess schedule for efficiency
- Request insurance certificates as necessary
- Review and process weekly field time cards
- Review previous day productivity
- Schedule monthly safety meetings
- Supervise organization and productivity of warehouse activities
- Supervise technicians, warehouse manager & dispatcher
Production Supervisor Job Responsibilities
- Ability to supervising – Supervisory responsibilities include interviewing, hiring, and training employees; planning, assigning, and directing work; appraising performance; rewarding and disciplining employees; addressing complaints and resolving problems.
- Analyzes and resolves work problems, or assists workers in solving work problems.
- Assists with other duties as directed by the supervisor.
- Compiles, stores, and retrieves production data.
- Conducts annual performance reviews utilizing the PEDS system for direct employees as well as midyear discussions and ongoing performance feedback.
- Confers with other supervisors to coordinate activities of individual departments.
- Develops or revises standard operational and working practices and observes workers to ensure compliance with standards.
- Ensure proper operation of presses and related equipment, requesting maintenance when necessary.
- Establishes or adjusts work procedures to meet production schedules.
- Inspects and approves all press set-ups. Continually monitors press operations including color reproduction, registration, speed, drying, and print quality.
- Inspects finished products to verify conformance to specifications and directs setup and adjustments of machines.
- Inspects machines and equipment to ensure specific operational performance and optimum utilization.
- Interprets and enforces company policies and safety regulations.
- Interprets printing specifications, blueprints, and job orders and assigns to production personnel.
- Maintains time and pressroom records.
- Monitor attendance according to attendance “points” system, utilizing timekeeping software (eTime) and attendance tracking software (Attendance Counts).
- Performs activities of workers supervised.
- Performs job according to pre-established safety, quality, and efficiency standard operating procedures.
- Plans production operations, establishing priorities and sequences for manufacturing products.
- Prepares operational schedules and coordinates manufacturing activities to ensure production and quality of products meets specifications.
- Recommends measures to improve production methods, equipment performance, and print quality.
- Resolves worker grievances or submits unsettled grievances to the Vice President of Operations for action.
- Responsible for the overall direction, coordination, and evaluation of 1-20 employees.
- Reviews production and operating reports and resolves operational, manufacturing, and maintenance problems to ensure minimum costs and prevent operational delays.
- Reviews production orders or schedules to ascertain product data such as types, quantities, and specifications of products and scheduled delivery dates in order to plan department operations.
- Studies production schedules and estimates labor hours required to complete printing jobs.
Technicians and Installers Job Responsibilities
- Accurately fills in the equipment tab in Field Desk Program
- Adheres to scheduled routes
- Communicates clearly and efficiently with customers
- Completes work correctly and efficiently and has minimal callbacks
- Enters accurate notes in the correct format
- Exhibits cooperation and teamwork
- Follows company procedures
- Follows company safety guidelines
- Has accurate timestamps in the Field Desk program as reflected by Fleetmatics Program
- Has safe driving habits as reflected by reports in Fleetmatics
- Installs doors within company guidelines
- Installs operators within company guidelines
- Is on time to work and does not take advantage of the time allowed for each job
- Keeps vehicle clean and organized
- Meets individual production goals
- Meets QB standards
- Neat and clean personal appearance including hair, facial hair, nails, hands, and clothing
- Produces accurate work orders to include all relevant data
- Uses phone and tablet appropriately and stays within permitted usage
- Wears correct uniform and is clean
Warehouse Manager Job Responsibilities
- Assist in any other area’s as necessary
- Complete daily truck stocking activity FiledOps to ensure technician parts usages match FieldOps.
- Control inventory
- Direct warehouse staff on materials to be loaded or on the assembly of items to be prepared for installation
- Ensure warehouse meets all safety standards i.e.walkways clear and free of hazards
- Keep warehouse organized, neat and clean
- Maintain product inventory & count in showroom cabinet
- Match product purchase delivery tickets with PO’s & enter in FieldOps
- Operate forklift
- Order & maintain safety equipment
- Order field & warehouse supplies
- Oversee delivery orders and exchange of product between locations
- Oversee the receipt and dispersal of materials entering the warehouse; help warehouse staff with this task when required
- Perform accurate monthly inventory count and reconcile to FieldOps
- Process RM’s monthly
- Produce reports regularly (in/out status report/ dead stock report etc.) as required by management
- Pull product for field techs daily work
- Receive & unload ODC truck deliveries, verify load sheet/ packing slips with PO’s, log receipts into FieldOps
- Replace monthly sign out sheets & present to Ops Mgr
- Report shortages to plant after truck delivery
- Review paperwork from all deliveries to determine if additional action is required
- RGA’s Liftmaster (over the phone)
- Secure warehouse facilities at the end of each day
- Stock product into the correct warehouse area
- Track & follow up on order for timely delivery
- Attention to Detail – Accuracy
- Awareness of Issues and Changes During the Day
- Completion of Daily Tasks
- Confidence in Decision Making
- Follows Procedures Consistently – Knowledge of and consistency in the following protocol in all situations. For example, missing unit protocol.
- Provides Consistent Support to all Drivers
Deliver High-Quality Work
- Effectively deals with conflict.
- Gets involved in making things better.
- Helps others to improve the quality of their work.
- Sets high standards for quality of work.
- Treats people fairly, without favoritism.
Draftsman Job Responsibilities
- 3D Modelling
- Completing full construction drawings & supporting documents.
- Ensure the final design complies with the regulation standard.
- Ensuring rack set updated for current projects.
- General Office Duties e.g. Backup, Site Bags, etc.
- Maintaining Template (Revit).
- Measuring sites & recording in AutoCAD/Revit.
- Meeting Clients and Presenting.
- On target Brand Ambassador (Dress, Attitude, Speaking, etc.)
- Photorealistic rendering.
- Shopfitting Sketches & Drawings.
- Support & Assist to the Design Team.
The production planning and management of Key Performance Indicators are a vital aspect of organizational success for the manufacturing concern. Tracking KPIs real-time adds further value to this process as it prevents negative short-term trends from evolving into major crises.
Manufacturing KPIs include all aspects of the product lifecycle from its design, prototype development and adoption, the management of product development timeline, the manufacturing and production capacity utilization rate, machinery set up and maintenance, reduction of machine downtime and optimization of machine uptime, health and safety best practices, employee training, product quality control, facility management, and product packaging and dispatch.