Hourly Production Report

What this template does#

The hourly report records each hour's target and actual good output for a line. It calculates the variance and the hourly efficiency from the garment SMV and manpower, and it totals the day. Its most useful column is the downtime reason: over a week, the reasons show where output is lost.

The report is based on the targets in production target calculation.

When to use it#

• Every day on every sewing line, filled at the end of each hour.
• In the daily production meeting, to review yesterday's losses.
• When investigating low line efficiency.

How to complete it#

1. Fill in date, line, style, SMV and manpower present at the start of the day.
2. Enter the hourly target for each hour. During the learning curve of a new style, targets may rise from hour to hour or day to day.
3. Record actual good output at the end of each hour, counted at the end-of-line check.
4. Record downtime in minutes and the main reason for any shortfall.
5. Review the day totals and day efficiency at the end of the shift.

Using the data#

• Group downtime reasons weekly and work on the largest.
• Compare hours: consistent shortfalls in the first hour or after breaks point to start-up and feeding problems.
• Keep reports by line and style for future target setting.

Common mistakes#

• Counting garments before end-of-line checking, so repairs are counted as output.
• Leaving the reason blank when the target is missed.
• Using planned manpower instead of manpower present.

Download formats#

The Excel workbook contains formulas and a landscape print layout. The CSV contains headings and example rows only.