Know where the line is slow. And what built every unit.
Predetermined time studies sit beside the actual cycle times your floor captures, so bottlenecks and capacity stop being guesswork. Every serial you ship carries its full kit-level lineage. Every component, every sub-assembly, every operator, every approval.
Target vs. actual. Every station
The cycle-time chart pairs target (from the engineering library) with actual (captured at build time) for every station on a line. Green where the floor is hitting takt, amber where it's drifting, red where the station is the line's bottleneck. Right-size capacity with the same data your operators feel, not estimates.
- Target vs. actual cycle time per workstation, last 7/30/90 days
- Bottleneck visible at a glance. Colour-coded against takt
- Actuals captured at build time. No manual stopwatch
- Roll-up by line / by plant / org-wide
- Equipment · Compressor100%
- Material · Kit not staged66%
- Equipment · Torque tool47%
- Labor · Operator change28%
- Planned · Maintenance22%
Three more charts you stop drawing in Excel
Throughput by day with a target overlay. Defect pareto by reason and sub-reason. So the brake-caliper line's "over tolerance. Bore" either drops or shows you exactly where to put the engineering hour. Downtime pareto by reason. Equipment, material, planned. So you fix root cause instead of arguing about it.
- Throughput chart with daily build counts + 7-day average
- Defect rate + pareto by category → sub-category
- Downtime pareto by reason with time + frequency
- Date-range chips: 7d / 30d / 90d, per line filter
- Sparky chart narration — one-line plain-language read on what each chart is actually showing, with the obvious next action
Full lineage for every serial
Pull any serial and see the tree: vehicle BC-260517-0023 ← caliper sub-assembly CA-26051-0019 ← rotor R-260517-091, harness H-260517-008, fasteners by lot. Every operator, every timestamp, every approval. The recall conversation goes from "we think we know" to "here are the 47 units affected, here is the operator at the join station, here is the WI revision that was published that day".
- Full upstream lineage captured at build commit. Never reconstructed
- Parallel sub-assemblies that merge into one parent serial
- Scan-required parent serials recorded with operator + timestamp
- Traceability without extra paperwork. Falls out of the build flow
Frequently asked questions
What manufacturing KPIs does Ignite Lean track?
Throughput, cycle time against target, downtime by reason, first-pass yield, labor cost per build, and the maintenance set of MTBF, MTTR, and PM compliance. They come from the build and downtime records the floor is already creating, not a separate data-entry step.
How is capacity or bottleneck analysis done?
Predetermined time studies sit next to the actual cycle times captured at each station, so the gap between planned and real is visible per station. The station with the longest real cycle relative to demand is the bottleneck, and you can see it rather than argue about it.
Do I need a data analyst to use the dashboards?
No. The dashboards ship configured, and the AI narration explains what a chart is showing in plain English. You can also ask the assistant a question about your own data instead of building a report.
The rest of Ignite Lean
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