How the System Calculates Production Time and Worker Efficiency
Every bundle scan on the device is data, and the system instantly turns it into accurate production time and real efficiency for each worker.What Is a Production Transaction?
A production transaction occurs whenever an employee scans a bundle on the device. The system reads the bundle's RFID tag to identify: the bundle number, production order, style, and all related information. It also knows the employee and the stages assigned to the device. With all this information combined, the system calculates production time and cost accurately.
How the System Calculates Time, Four Scenarios
Scenario 1: Single Stage, The Basic Case
A worker assigned to a device with one stage. The bundle contains 30 pieces. Time between the last scan (10:20 AM) and this scan (10:30 AM) = 10 minutes.
- Estimated stage time: 0.25 minutes per piece, so 7.5 minutes for the full bundle.
- Actual time: 10 minutes, or 0.33 minutes per piece.
- Result: worker efficiency drops because actual time is slower than estimated.
Scenario 2: Bundle Group
A group of 3 bundles: Bundle 1 (10 pieces), Bundle 2 (15 pieces), Bundle 3 (15 pieces), totaling 40 pieces. Time between scans: 120 minutes (11:00 AM — 1:00 PM).
- Estimated stage time: 1.5 minutes per piece.
- Actual total time: 120 minutes for 40 pieces = 3 minutes per piece.
- Time distribution: Bundle 1 = 30 minutes, Bundle 2 = 45 minutes, Bundle 3 = 45 minutes.
- Result: actual time is significantly slower than estimated, indicating a major drop in efficiency.
Scenario 3: Bundle Group With a Break
Same as Scenario 2, with a break from 12:00 PM to 12:30 PM.
- Net time after deducting the break: 120 - 30 = 90 minutes.
- Actual time: 90 minutes for 40 pieces = 2.25 minutes per piece.
- Time distribution: Bundle 1 = 22.5 minutes, Bundle 2 = 33.75 minutes, Bundle 3 = 33.75 minutes.
- Result: better than Scenario 2, but still needs improvement.
Scenario 4: Multiple Stages at Once
A worker operating two stages simultaneously. Bundle contains 10 pieces. Time between scans: 20 minutes.
- Estimated time: Stage 1 at 2 minutes per piece (20 minutes for the bundle), Stage 2 at 1 minute per piece (10 minutes for the bundle).
- Actual total time: 20 minutes distributed by weight ratio — Stage 1 gets 13.3 minutes (1.33 minutes per piece), Stage 2 gets 6.7 minutes (0.67 minutes per piece).
- Result: worker efficiency is high because production is faster than estimated.
Important Notes
Break times, stoppages, and maintenance periods are automatically deducted from the total time between two production transactions, since the worker was not producing during those periods.
Real-world scenarios often combine multiple stages and break times. This guide covers the fundamentals — the system handles more complex scenarios automatically.
Frequently Asked Questions
- How does the system know the worker was on a break rather than working?
The system automatically deducts recorded break, stoppage, and maintenance times from the total time between two production transactions. - How is time distributed when working on multiple stages at once?
The actual time is distributed across stages proportionally based on their weights — each stage receives a share of the total time proportional to its estimated time. - What happens when a bundle group is scanned all at once?
The system distributes the total time across bundles in proportion to the number of pieces in each one. - Do stoppage and maintenance times affect the efficiency calculation?
No, these periods are excluded from the calculation because the worker was not in a production state during them.
The system automatically deducts recorded break, stoppage, and maintenance times from the total time between two production transactions.
The actual time is distributed across stages proportionally based on their weights — each stage receives a share of the total time proportional to its estimated time.
The system distributes the total time across bundles in proportion to the number of pieces in each one.
No, these periods are excluded from the calculation because the worker was not in a production state during them.
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