Theoretical Plan (IE Std)

UPH Shift Target

UPH Shift Total no of
S.No Date Shift (100% ( @ 100%
(90% eff) Hrs lines
eff) Eff )
1 4-Oct A 111 100 7.5 1 833
2 4-Oct B 111 100 7.5 1 833
3 5-Oct A 111 100 7.5 1 833
4 16-Oct A 111 100 7.5 1 833
5 16-Oct B 111 100 7.5 1 833
6 17-Oct A 111 100 7.5 1 833
7 17-Oct B 111 100 7.5 1 833
8 18-Oct A 111 100 7.5 1 833
9 18-Oct B 111 100 7.5 1 833
10 19-Oct A 111 100 7.5 1 833
11 19-Oct B 111 100 7.5 1 833
12 20-Oct A 111 100 7.5 1 833
13 20-Oct B 111 100 7.5 1 833
14 21-Oct A 111 100 7.5 1 833
15 21-Oct B 111 100 7.5 1 833
16 25-Oct A 111 100 7.5 1 833
17 25-Oct B 111 100 7.5 1 833
18 26-Oct A 111 100 7.5 1 833
19 26-Oct B 111 100 7.5 1 833
20 27-Oct A 111 100 7.5 1 833
21 27-Oct B 111 100 7.5 1 833
22 28-Oct A 111 100 7.5 1 833
23 28-Oct B 111 100 7.5 1 833
24 29-Oct A 111 100 7.5 1 833
25 29-Oct B 111 100 7.5 1 833
26 30-Oct A 111 100 7.5 1 833
27 30-Oct B 111 100 7.5 1 833
28 31-Oct A 111 100 7.5 1 833
29 31-Oct B 111 100 7.5 1 833

Total
#REF! #REF!
111.11111111
Production Actual
Gap
Plan(PP) Output
Build Actual
Startup Loss Changeover Loss/
plan output Gap (in Nos )
( 5S / Meeting ) Power trip
( in Nos) (in Nos )
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 2 -747
749 100 -649
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 0 -749
749 1 -748
749 0 -749
749 0 -749
749 0 -749
749 6 -743
749 0 -749
749 0 -749
749 0 -749
749 491 -258
749 340 -409
749 160 -589

4496 1100 -3396 0 0

 Losses
Losses due to
Test Machine Printer / Label IT / MES / Process /
Material Losses
Breakdown Breakdown Server Loss Screw driver /
Jigs

Material shorttage
Material shorttage

0 0 0 0 0
 Efficiency Loss
Line stoppage Units Gap
due to HC ( New Total Loss
due to Quality No Plan due to DT (
HC / Under in mins
issues (Mins) in Nos )
training etc )
No plan 0 0
No plan 0 0
shorttage No plan 0 0
shorttage No plan 0 0
No plan 0 0
No plan 0 0
0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
No plan 0 0
0
0 0
0 0

0 0 0 0 0
 Resource UPPH as per Build Plan (
Target UPPH ( Actual UPPH
Achievement
Standard Actual Shift ( Shift
Gap Gap Ratio ratio
HC as per IE HC Cumulative ) Cumulative )
( @90% Eff)
@ 90% Eff @ 90% Eff
71 10 -61 -86% 10.55 0.00 0.00%
71 13 -58 -82% 10.55 0.00 0.00%
71 10 -61 -86% 10.55 0.00 0.00%
71 12 -59 -83% 10.55 0.00 0.00%
71 23 -48 -68% 10.55 0.00 0.00%
71 26 -45 -63% 10.55 0.08 0.73%
71 29 -42 -59% 10.55 3.45 32.68%
71 26 -45 -63% 10.55 0.00 0.00%
71 27 -44 -62% 10.55 0.00 0.00%
71 26 -45 -63% 10.55 0.00 0.00%
71 27 -44 -62% 10.55 0.00 0.00%
71 23 -48 -68% 10.55 0.00 0.00%
71 23 -48 -68% 10.55 0.00 0.00%
71 26 -45 -63% 10.55 0.00 0.00%
71 36 -35 -49% 10.55 0.00 0.00%
71 38 -33 -46% 10.55 0.00 0.00%
71 30 -41 -58% 10.55 0.00 0.00%
71 35 -36 -51% 10.55 0.00 0.00%
71 27 -44 -62% 10.55 0.04 0.35%
71 38 -33 -46% 10.55 0.00 0.00%
71 39 -32 -45% 10.55 0.00 0.00%
71 40 -31 -44% 10.55 0.00 0.00%
71 42 -29 -41% 10.55 0.14 1.35%
71 35 -36 -51% 10.55 0.00 0.00%
71 27 -44 -62% 10.55 0.00 0.00%
71 48 -23 -32% 10.55 0.00 0.00%
71 70 -1 -1% 10.55 7.01 66.47%
71 45 -26 -37% 10.55 7.56 71.60%
71 54 -17 -24% 10.55 2.96 28.08%

426 279 -147 -34.5% 10.55 3.94 37.4%

as per Build Plan ( @ 90% Efficiency ) UPPH as per 100% Eff
Target UPPH
( Shift
Remarks Cumulative )
@ 100% Eff
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
11.73
UPPH as per 100% Eff
Actual UPPH (
Shift Achievement ratio
Cumulative ) ( @100% Eff)
@ 100% Eff
0.00 0.00% 0.0% 0 106 106
0.00 0.00% 0.0% 0 137 137
0.00 0.00% 0.0% 0 106 106
0.00 0.00% 0.0% 0 127 127
0.00 0.00% 0.0% 0 243 243
0.08 0.66% -0.7% -5 274 272
3.45 29.41% -32.7% -245 306 206
0.00 0.00% 0.0% 0 274 274
0.00 0.00% 0.0% 0 285 285
0.00 0.00% 0.0% 0 274 274
0.00 0.00% 0.0% 0 285 285
0.00 0.00% 0.0% 0 243 243
0.00 0.00% 0.0% 0 243 243
0.00 0.00% 0.0% 0 274 274
0.00 0.00% 0.0% 0 380 380
0.00 0.00% 0.0% 0 401 401
0.00 0.00% 0.0% 0 317 317
0.00 0.00% 0.0% 0 369 369
0.04 0.32% -0.4% -3 285 284
0.00 0.00% 0.0% 0 401 401
0.00 0.00% 0.0% 0 412 412
0.00 0.00% 0.0% 0 422 422
0.14 1.22% -1.4% -10 443 437
0.00 0.00%
0.00 0.00%
0.00 0.00%
7.01 59.82%
7.56 64.44%
2.96 25.27%
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
 #REF! #REF! #REF! #REF! #REF! #REF! #REF! 10.9
#REF! 171
Overall Overall
Overall Build Overall Actual Overall Gap Overll Gap
Date Loss in Units Gap
Plan output (In No's) Ratio
#REF! Mins due to DT

#REF! 4-Oct 749 0 -749 -100.0% 61 597

5-Oct 749 0 -749 -100.0% 6 56
#REF! 16-Oct 749 0 -749 -100.0% 252 2447
17-Oct 749 102 -647 -86.4% 180 1745
6.935185 18-Oct 749 0 -749 -100.0% 176 1713
48.5463 19-Oct 749 0 -749 -100.0% 134 1300
20-Oct 749 0 -749 -100.0% 179 1744
21-Oct 749 0 -749 -100.0% 204 1980
25-Oct 749 0 -749 -100.0% 119 1153
18.81709 26-Oct 749 1 -748 -99.9% 119 1153
27-Oct 749 0 -749 -100.0% 140 1359
18.81709 28-Oct 749 6 -743 -99.2% 91 887
30-Oct 749 491 -258 -34.4% 82 798
31-Oct 749 500 -249 -33.2% 15 148
#REF!
Total 10486 1100 -9386 -89.5% #REF! #REF!

#REF!
 #REF! 0.3303612 2783.984 #REF! 1250 491.75
0.018737616217
Overall Actual
Target UPPH Overall
UPPH
Overall HC As Overall Overall Overall Gap ( Shift Achievement
( Shift
per IE Actual HC Gap Ratio Cumulative ) @ ratio
Cumulative ) @
90% Eff ( @90% Eff)
90% Eff
148 24 -124 -83.78% 5.06 0.00 0.0%
148 76 -72 -48.65% 5.06 0.00 0.0%
148 84 -64 -43.24% 5.06 0.00 0.0%
108 63 -45 -41.67% 6.94 1.62 23.3%
108 61 -47 -43.52% 6.94 0.00 0.0%
108 44 -64 -59.26% 6.94 0.00 0.0%
108 59 -49 -45.37% 6.94 0.00 0.0%
108 67 -41 -37.96% 6.94 0.00 0.0%
108 39 -69 -63.89% 6.94 0.00 0.0%
108 39 -69 -63.89% 6.94 0.03 0.4%
108 46 -62 -57.41% 6.94 0.00 0.0%
108 30 -78 -72.22% 6.94 0.20 2.9%
108 27 -81 -75.00% 6.94 18.19 262.2%
108 5 -103 -95.37% 6.94 100.00 1441.9%

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! 96%
#REF! #REF!
#REF!
Remarks

84.21%
2.50%
98.55%
93.72%
95.01%
100.00%
100.00%
100.00%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
 11824

18232.00
597 61
56 6
2447 252
1745 180
1713 176
1300 134
1744 179
1980 204
1153 119
1153 119
1359 140
887 91
798 82
148 15
 Overall
Overall Gap Overll Gap
Month Overall Build Plan Actual
(In No's) Ratio
output

OCT 10486 1100 -3396 -32.4%

Loss Break-up with Remark

Total Total Total
S:No Description Loss In Loss in Loss in
Qty Mins Hrs

Critical HC Retained. Deployed to

1 clear Defects Units including Previous 35151 27153 452.5
station and Ageing Issue from BLT
Line Down due to Bottom housing
2 Unavailable and Flex Mould Top 1458 1126 18.8
Housing and PCBA Fitting Issue

Line Down due to MRP Label

3 4982 3848 64.1
Unavailable

Line Down due to Foot rubber

4 1021 789 13.1
Unavailable

Cummulative 42612 548.60

 Overall Loss in Overall Units Overall Overall
Overall HC As per IE Overall Actual HC
Mins Gap due to DT Gap Gap Ratio

0 0 909 909 -147 -34.5%

with Remarks
Overall HC Overall DL Cost
Per Hour Percentage Of
as per (Loss due to GB
Cost of DL Loss Qty
IE/Shift Unavailable)

148 114 ₹ 7,654,472 335.2%

148 114 ₹ 317,494 13.9%

148 114 ₹ 1,084,879 47.5%

148 114 ₹ 222,333 9.7%

₹ 9,279,178
 Overall Actual UPPH Overall Achievement
Target UPPH ( Shift
( Shift Cumulative ) ratio
Cumulative ) @ 90% Eff
@ 90% Eff ( @90% Eff)

10.55 3.94 37.4%

259

Unit/1 Min 1.3

14.3888888888889

Unit/1 HC 11.54

Overall Loss Qty 406.4%

32916.002288766
3693.90692351707
2955125.53881366
 Remarks

DL cost impact due to 200A Back end Down for below Issues from
1st Sep - 30th Sep - 42612 No's - 35.4%
1st Sep - 30th Sep - Production Plan - 77753: Achieved - 74579 (96% )
1. Critical HC Retained - During 200A Ramp-Down (No Attrition) - 35151 No's - 29.2%
A. Bad-WIP cleared - 122 HC - 31200 No's
B. In-Efficiency Loss - 137 HC - 35151 No's
Average : 14HC/Day - Critical HC utilized in Ramp-Down.
2. Line Down due to PCBA Facing Previous Station and Ageing Issue - 12727 No's - 10.6%
3. Line Down due to MRP Label unavailable. - 4982 No's - 4.1%
4. Line Down due to Bottom Housing unavailable + Fitment Issue. - 1458 No's - 1.2%
5. Line Down due to Foot rubber unavailable. - 1021 No's - 0.8%

0.959178423983641
1-Aug-23 2-Aug-23 3-Aug-23 4-Aug-23 5-Aug-23 6-Aug-23
25988 19491 19491 21491 25988 0
22301 20681 20759 21132 22058 0
7-Aug-23 8-Aug-23 9-Aug-23 10-Aug-23 11-Aug-23 12-Aug-23
27988 25988 25988 25988 0 25988
25388 22850 25157 26029 0 19314
 August-2023 Production Plan
13-Aug-23 14-Aug-23 15-Aug-23 16-Aug-23 17-Aug-23 18-Aug-23
28188 28188 0 25988 25988 25988
27711 27384 0 26109 23618 27026
n Plan
19-Aug-23 20-Aug-23 21-Aug-23 22-Aug-23 23-Aug-23 24-Aug-23
25988 0 25988 25988 25988 25988
26446 0 26614 27477 26418 24383
25-Aug-23 26-Aug-23 27-Aug-23 28-Aug-23 29-Aug-23 30-Aug-23
25041 25988 0 0 0 0
21017 20213 0 0 0 0
31-Aug-23 Total
19491 579189
21188 551273
 Total DL cost Incurrence due to
Production Ramp Up ( JM SC 200A ) ₹ 2,069,040

800
Date Line No HC Planned Ramp-Up % Production Plan Actual Output
1-Jul-23 1
2-Jul-23 1
3-Jul-23 1
4-Jul-23 1
5-Jul-23 1
6-Jul-23 1
7-Jul-23 1
8-Jul-23 1
9-Jul-23 1
10-Jul-23 1
11-Jul-23 1
12-Jul-23 1
13-Jul-23 1
14-Jul-23 1
15-Jul-23 1
16-Jul-23 1
17-Jul-23 1
18-Jul-23 1
19-Jul-23 1
20-Jul-23 1
21-Jul-23 1
22-Jul-23 1
23-Jul-23 1
24-Jul-23 1
25-Jul-23 1
26-Jul-23 1
27-Jul-23 1
28-Jul-23 1
29-Jul-23 1
30-Jul-23 1
31-Jul-23 1
0 0 0

136675
 ₹0
Line 1
Ramp up Loss/HC (INR) Ramp up Loss overall HC (INR) Date Line No
1-Jul-23 2
2-Jul-23 2
3-Jul-23 2
4-Jul-23 2
5-Jul-23 2
6-Jul-23 2
7-Jul-23 2
8-Jul-23 2
9-Jul-23 2
10-Jul-23 2
11-Jul-23 2
12-Jul-23 2
13-Jul-23 2
14-Jul-23 2
15-Jul-23 2
16-Jul-23 2
17-Jul-23 2
18-Jul-23 2
19-Jul-23 2
20-Jul-23 2
21-Jul-23 2
22-Jul-23 2
23-Jul-23 2
24-Jul-23 2
25-Jul-23 2
26-Jul-23 2
27-Jul-23 2
28-Jul-23 2
29-Jul-23 2
30-Jul-23 2
31-Jul-23 2

180658 188466
 800 Line 2
HC Planned Ramp-Up % Production Plan Actual Output Ramp up Loss/HC (INR)

0 0 0

43983

-7808
 ₹0
800
Ramp up Loss overall HC (INR) Date Line No HC Planned Ramp-Up %
1-Jul-23 3 222 40%
2-Jul-23 3
3-Jul-23 3 222 50%
4-Jul-23 3 222 60%
5-Jul-23 3 222 75%
6-Jul-23 3 222 90%
7-Jul-23 3
8-Jul-23 3
9-Jul-23 3
10-Jul-23 3
11-Jul-23 3
12-Jul-23 3
13-Jul-23 3
14-Jul-23 3
15-Jul-23 3
16-Jul-23 3
17-Jul-23 3
18-Jul-23 3
19-Jul-23 3
20-Jul-23 3
21-Jul-23 3
22-Jul-23 3
23-Jul-23 3
24-Jul-23 3
25-Jul-23 3
26-Jul-23 3
27-Jul-23 3
28-Jul-23 3
29-Jul-23 3
30-Jul-23 3
31-Jul-23 3
1110
 ₹ 328,560
Line 3
Production Plan Actual Output Ramp up Loss/HC (INR) Ramp up Loss overall HC (INR)
2,599 1964 480 106560

3,249 0 400 88800

3,898 608 320 71040
4,873 4,150 200 44400
5,847 5,650 80 17760

20466

43983
 800
Date Line No HC Planned Ramp-Up % Production Plan Actual Output
1-Jul-23 4
2-Jul-23 4
3-Jul-23 4
4-Jul-23 4
5-Jul-23 4
6-Jul-23 4 222 5% 325 490
7-Jul-23 4 222 10% 800 2,205
8-Jul-23 4 222 25% 1,624 1,928
9-Jul-23 4
10-Jul-23 4 222 40% 2,599 2578
11-Jul-23 4 222 50% 3,249 3641
12-Jul-23 4 222 60% 3,898 2433
13-Jul-23 4 222 75% 4,873 2,120
14-Jul-23 4 222 90% 5,847 4,667
15-Jul-23 4
16-Jul-23 4
17-Jul-23 4 222 15% 975 1161
18-Jul-23 4 222 25% 1,624 3019
19-Jul-23 4 222 40% 2,599 1950
20-Jul-23 4 222 60% 3,898 2,986
21-Jul-23 4 222 75% 4,982 1,750
22-Jul-23 4 222 90% 5,847 5,589
23-Jul-23 4
24-Jul-23 4
25-Jul-23 4
26-Jul-23 4
27-Jul-23 4
28-Jul-23 4
29-Jul-23 4
30-Jul-23 4
31-Jul-23 4
3108 43140

43983
 ₹ 1,314,240
Line 4
Ramp up Loss/HC (INR) Ramp up Loss overall HC (INR) Date Line No
1-Jul-23 5
2-Jul-23 5
3-Jul-23 5
4-Jul-23 5
5-Jul-23 5
760 168720 6-Jul-23 5
720 159840 7-Jul-23 5
600 133200 8-Jul-23 5
9-Jul-23 5
480 106560 10-Jul-23 5
400 88800 11-Jul-23 5
320 71040 12-Jul-23 5
200 44400 13-Jul-23 5
80 17760 14-Jul-23 5
15-Jul-23 5
16-Jul-23 5
680 150960 17-Jul-23 5
600 133200 18-Jul-23 5
480 106560 19-Jul-23 5
320 71040 20-Jul-23 5
200 44400 21-Jul-23 5
80 17760 22-Jul-23 5
23-Jul-23 5
24-Jul-23 5
25-Jul-23 5
26-Jul-23 5
27-Jul-23 5
28-Jul-23 5
29-Jul-23 5
30-Jul-23 5
31-Jul-23 5
 800 Line 5
HC Planned Ramp-Up % Production Plan Actual Output Ramp up Loss/HC (INR)

222 10% 650 0 720

222 20% 1,299 0 640

222 30% 1,949 0 560

666 3898

43983
 ₹ 426,240
Ramp up Loss overall HC (INR)

159840
142080

124320
 800
Date Line No HC Planned Ramp-Up % Production Plan Actual Output
1-Jun-23 1 225 32% 2,103 1,990
2-Jun-23 1 225 28% 1,800 1,854
3-Jun-23 1 225 45% 2,904 2,699
5-Jun-23 1 225 77% 5,001 5,008
6-Jun-23 1 225 78% 5,078 5,178
7-Jun-23 1 225 89% 5,760 5,787
8-Jun-23 1 225 100% 6,497 3,373
9-Jun-23 1 225 100% 6,497 4,751
10-Jun-23 1 225 100% 6,497 4,204
12-Jun-23 1 225 100% 6,497 6,719
13-Jun-23 1 225 100% 6,497 4,284
14-Jun-23 1 225 100% 6,497 6,261
15-Jun-23 1 225 100% 6,497 5,513
16-Jun-23 1 225 100% 6,497 6,038
17-Jun-23 1 225 100% 6,497 6,445
19-Jun-23 1 225 100% 6,497 6,200
20-Jun-23 1 225 100% 6,497 2,406
21-Jun-23 1 225 100% 6,497 6,318
22-Jun-23 1 225 100% 6,497 6,085
23-Jun-23 1 225 100% 6,497 6,500
24-Jun-23 1 225 100% 6,497 6,788
26-Jun-23 1 225 100% 6,497 6,288
27-Jun-23 1 225 100% 6,497 6,111
28-Jun-23 1 225 100% 6,497 6,250
29-Jun-23 1 225 100% 6,497 6,445
30-Jun-23 1 225 100% 6,497 7,180
5850 152586 136675

136675
Ramp up Loss/HC (Rs) Ramp up Loss overall HC (Rs) Date Line No
541 121736 1-Jun-23 2
578 130131 2-Jun-23 2
442 99544 3-Jun-23 2
184 41447 5-Jun-23 2
175 39314 6-Jun-23 2
91 20419 7-Jun-23 2
0 0 8-Jun-23 2
9-Jun-23 2
10-Jun-23 2
12-Jun-23 2
13-Jun-23 2
14-Jun-23 2
15-Jun-23 2
16-Jun-23 2
17-Jun-23 2
19-Jun-23 2
20-Jun-23 2
21-Jun-23 2
22-Jun-23 2
23-Jun-23 2
24-Jun-23 2
26-Jun-23 2
27-Jun-23 2
28-Jun-23 2
29-Jun-23 2
30-Jun-23 2

180658 188466
 800
HC Planned Ramp-Up % Production Plan Actual Output Ramp up Loss/HC (Rs)

219 5% 325 609 760

219 10% 650 0 720
219 10% 650 0 720
219 25% 1,624 0 600
219 40% 2,599 0 480
219 50% 3,249 0 400
219 50% 3,249 1,762 400
219 60% 3,898 0 320
219 75% 4,873 0 200
219 90% 5,847 2,100 80
219 100% 6,497 3,523 0
219 100% 6,497 6,788
219 100% 6,497 6,288
219 100% 6,497 6,111
219 100% 6,497 3,227
219 100% 6,497 6,445
219 100% 6,497 7,130
3723 72442 43983

43983

-7808
 800
Ramp up Loss overall HC (Rs) Date Line No HC Planned Ramp-Up %
1-Jun-23 3
2-Jun-23 3
3-Jun-23 3
5-Jun-23 3
6-Jun-23 3
7-Jun-23 3
8-Jun-23 3
9-Jun-23 3
10-Jun-23 3
166440 12-Jun-23 3
157680 13-Jun-23 3
157680 14-Jun-23 3
131400 15-Jun-23 3
105120 16-Jun-23 3
87600 17-Jun-23 3
87600 19-Jun-23 3
70080 20-Jun-23 3
43800 21-Jun-23 3
17520 22-Jun-23 3
0 23-Jun-23 3
24-Jun-23 3
26-Jun-23 3
27-Jun-23 3
28-Jun-23 3 222 5%
29-Jun-23 3 222 10%
30-Jun-23 3 222 25%
666
Production Plan Actual Output Ramp up Loss/HC (Rs) Ramp up Loss overall HC (Rs)

325 0 760 168720

650 0 720 159840
1,624 0 600 133200
2599

43983