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“What Gets Measured,gets rectified”

Recording Data is the first step of improvement,production report is no different.

Production Report

Production report or Daily production Report(DPR) is a recording document ,through which daily production activity conducted at shop floor are recorded.

It’s a very useful tool for monitoring current production systems.It helps improve production system,provided right actions are taken.

Purpose of production report is as follow :

1. Record attributes which are important for production system.
2. Analyse recorded attributes,to come up with actionable points.
3. Take action on derived actionable points.
4. Repeat the process.
5. More over DPR is important from trace ability purpose.

Parameters to be captured in production Report

” No input,No Output”

Every input you give has certain expected output in your mind.I have listed down output for each input field on DPR. This will help you understand why we are recording all these inputs in DPR

Serial No.

It provides a unique ID to each and every entry on production report.

Date

The date is important from the trace-ability perspective making it an important part of DPR.

Shift

Things tend to vary with production shifts(day shift ; night shift).People have tendency to get complacent in night shifts.Including shift in DPR would make such cases visible.

Route Card No

A route card is a movement card used to record all the process details of a particular issued RM lot.

Part Number

It help us do micro analysis for part wise sales trend,defect trends,productivity trends,etc.

Total Qty produced

This works in conjunction with 5th point.

Total NG parts

It is the measure of total defective parts produced. There is a total of 7 types of waste.Transportation,inventory,motion,waiting,overproduction,over-processing and defects(TIM WOOD).An important part of lean manufacturing is reducing waste. This parameter measures the defected part of total waste.

Rejection types

Only to know total rejection doesn’t help. We need to find major contributors as well.

Reworked Quantity

This parameter records the amount of rejection. It reflects the amount of rejection that can be reworked.

It is a non-value added activity.We need to reduce it.

Machine Number

Recording Machine no. helps capture machine wise production and breakdown trend.It helps calculate OEE as well.

Operation name

It helps us find process wise production, WIP status,trace-ability.

Tool number

Recording tool no. helps in tool life monitoring.

Down Time

It helps us calculate OEE.

Down time reason

Capturing machine no. and downtime helps us pin point problematic machine.Next step is details of problem causing that down time.

Setting time

Setting time is an non value adding activity.It provides measurable targets to reduce waste.

These are the important aspects of DPR.

All the above-mentioned points are integral to DPR. These points help get the maximum out of DPR.

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