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DATUM FIELD CHAPTER · PRODUCTION

Discipline: Production

Ten canonical operational blueprints cataloged under the Production field domain.

#021
Production Analytics

We don't know what to produce tomorrow

Which products should use tomorrow's limited capacity?

#021 Lot-Sizing MPS125 Units / Batch
Setup vs Holding Tradeoff10 Setup Cycles
Batch Size:125 units
Total Setups:10 runs / mo
Small Batches (JIT)Large Batches (EOQ)
Verified ProofBlueprint→
#022
Production Analytics

Production plans keep changing

How resilient is the schedule to new information?

#022 SMED Setup28m Machine Stop
STOP: 28mRUNNING PREP: 30m
Downtime Reduction38% Saved
Internal Stop Time:28 mins
Capacity Gained:+17m / shift
Baseline SetupSMED Converted
Verified ProofBlueprint→
#023
Production Analytics

Machines are underutilized

Where is capacity sitting idle?

#023 OEE Waterfall65% OEE
85%AVAIL×83%PERF×92%QUAL
World Class Standard: >85%Hidden Factory Loss
Net Utilization:65% Effective
Loss Scrap/Downtime:35% Lost
UncalibratedOptimized Line
Verified ProofBlueprint→
#024
Theory of Constraints

One bottleneck slows the entire plant

Which stage limits total throughput?

#024 Line Flow Simulation60 u/hr Bottleneck
120
Milling
60
CHOKE
Assembly
100
Testing
140
Packing
⚠ Assembly Constrains OutputMax Cap: 140u
OUTPUT:480 u/shift
BOTTLENECK:Assembly (60/h)
💡Improving non-bottlenecks creates inventory backlog.
Blueprint→
#025
Production Analytics

Changeovers consume too much time

How should sequence and batch size balance setups and inventory?

#025 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→
#026
Production Analytics

Orders compete for limited capacity

Which orders should get scarce capacity first?

#026 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→
#027
Production Analytics

Production and demand plans do not match

Where do the plans diverge?

#027 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→
#028
Production Analytics

We struggle to prioritize urgent orders

Which job should go first?

#028 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→
#029
Production Analytics

We don't know whether to make now or later

When does early production become expensive inventory?

#029 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→
#030
Production Analytics

Production schedules are created manually

Can a better sequence reduce total completion time?

#030 Line Synchrony100 u/hr
ST-1ST-2ST-3ST-4ST-5
Takt: 36s / unitFlow Balanced
Takt Cycle:36s
Shift Output:800 units
Starved LineMax Takt Flow
Verified ProofBlueprint→