Summary

Provides a tabular presentation of key metrics for either a process or a selected portion of a process. This report is most useful on projects based on improving the flow or quality of work on an entire process or a selected section of a process (for example, projects based on Lean-type defect metrics such as "excessive inventory" or "excessive cycle time").

The Cumulative Metrics report presents the:
  • Throughput yield (YTP) for each selected step and the rolled throughput yield
  • Cycle time for each selected step and the overall cycle time
  • Cost per selected step and the overall cost
  • The queue per selected step and the sum of the queues (the WIP inventory)
Answers the question:
  • How good or bad is the process (or the selected scope of the process) based on the key metrics of yield, time, cost, and inventory?
When to Use Purpose
Start of project Define the performance of the baseline process (or selected section) in terms of the key metrics of yield, time, cost, and inventory.
Mid-project Play "what-if" with potential step improvements and calculate the expected effect on the entire process (or selected section).
End of project Define the performance of the final process (or selected section) in terms of the key metrics of yield, time, cost, and inventory.

Data

Step data for yield, time, cost, and queues entered in Process Data and Lean Data.

How-To

  1. This tool requires the construction of a process map.
  2. With the blank Cumulative Metrics tool open, click to "Add Rows" and select either all rows (steps/shapes) or a selected subset of the rows.
  3. You can enter the data for the Cumulative Metrics report either directly in the report or in the process map itself.
  4. When entering data in a process map, you need to enter the following data in this order to calculate the data needed for the cumulative metrics:
    1. In the Process section, enter Scrap % and Rework %.
    2. In the Lean section, enter Cycle Time, Cost per Unit, and Average Queue.
  5. If the data are entered in the process map, the following fields load automatically when you add an activity to the cumulative metrics table:
    • Ytp (Yield)
    • Cycle Time
    • Cost per Unit
    • Average Queue
  6. You can change any of these values (except Ytp) by editing them in the table.
  7. If the data are not entered in the process map, enter the following values in the cumulative metrics table:
    • Cycle Time
    • Cost per Unit
    • Average Queue
  8. Enter any appropriate conclusions in the provided space.

Guidelines

  • If you are not interested in and did not enter Queue analysis data, the remaining metrics will be properly presented.
  • You may want to define Cycle Time as you mean it to be (you can enter a note into the Conclusions box).
  • The Cumulative Rolled Throughput Yield can be a very impressive metric. Even in processes that consist of relatively good individual processes, the complexity of multiple steps can cause a very low rolled throughput (the probability of a unit making it through the entire process without being scrapped or reworked).
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