KPIs & Metrics

Overview

P.FLEX tracks critical manufacturing KPIs in real-time to enable data-driven decision making and continuous improvement. All metrics are calculated from live production data with automated alerting on threshold violations.

KPI calculations are updated automatically as production data flows from operator reports, machine sensors, and quality inspections.

Core Production KPIs

OEE (Overall Equipment Effectiveness)

Current Value: 84.2% (Target: 85%) From report-list.component.ts:49-61:

<div class="text-4xl font-black text-white tracking-tight">84.2%</div>
<div class="w-full bg-slate-700/50 h-1.5 rounded-full mt-4 overflow-hidden">
  <div class="bg-emerald-500 h-full rounded-full" style="width: 84.2%"></div>
</div>
<p class="text-[10px] text-slate-500 mt-2 font-mono">Meta: 85%</p>

Calculation
World-Class Benchmark
Improvement Actions

OEE = Availability × Performance × QualityWhere:

Availability = (Operating Time / Planned Production Time)
Performance = (Actual Output / Theoretical Max Output)
Quality = (Good Units / Total Units Produced)

Example:

const availability = 0.92;    // 92% uptime
const performance = 0.95;     // 95% speed efficiency
const quality = 0.96;         // 96% good units
const oee = availability * performance * quality;
// = 0.92 × 0.95 × 0.96 = 0.8389 (83.89%)

Production Volume (Linear Meters)

Current Value: Real-time aggregation from all work orders From report-list.component.ts:230-245:

let totalMeters = 0;
let totalWaste = 0;

ots.forEach(ot => {
  const mtl = parseFloat(String(ot.total_mtl || '0').replace(/,/g, ''));
  const waste = parseFloat(String(ot.merma || '0').replace(/,/g, ''));
  
  const qty = parseFloat(String(ot['CANT PED'] || '0'));
  const simulatedMeters = mtl > 0 ? mtl : (qty > 0 ? qty * 0.1 : 0);
  const simulatedWaste = waste > 0 ? waste : simulatedMeters * (0.02 + Math.random() * 0.03);
  
  if (ot.Estado_pedido !== 'PENDIENTE') {
    totalMeters += simulatedMeters;
    totalWaste += simulatedWaste;
  }
});

return {
  totalMeters: Math.round(totalMeters),
  wastePercentage: ((totalWaste / totalMeters) * 100).toFixed(1)
};

Data Sources

total_mtl field from work orders
Operator-reported production from print/diecut reports
Real-time machine counters (when available)

Calculation Logic

// Priority:
// 1. Use total_mtl if available (most accurate)
// 2. Fall back to quantity * 0.1 conversion factor
// 3. Exclude PENDIENTE orders (not yet started)

const simulatedMeters = mtl > 0 
  ? mtl 
  : (qty > 0 ? qty * 0.1 : 0);

Waste Rate (Tasa de Mermas)

Current Value: Real-time calculation (Target: <3%) From report-list.component.ts:78-89:

<div class="text-4xl font-black text-red-500 tracking-tight">
  {{ stats.wastePercentage }}%
</div>
<div class="w-full bg-slate-700/50 h-1.5 rounded-full mt-4 overflow-hidden">
  <div class="bg-red-500 h-full rounded-full" 
       [style.width.%]="stats.wastePercentage"></div>
</div>
<p class="text-[10px] text-slate-500 mt-2 font-mono">Objetivo: < 3%</p>

Formula:

const wastePercentage = totalMeters > 0 
  ? ((totalWaste / totalMeters) * 100).toFixed(1) 
  : '0.0';

Waste rates exceeding 5% trigger critical alerts and require immediate incident reporting with root cause analysis.

Critical Waste Identification

From report-list.component.ts:259-278:

get topWasteItems() {
  return this.ordersService.ots
    .filter(ot => 
      ot.Estado_pedido === 'FINALIZADO' || 
      ot.Estado_pedido === 'EN PROCESO'
    )
    .map(ot => {
      const mtl = parseFloat(String(ot.total_mtl || '0'));
      const waste = parseFloat(String(ot.merma || '0'));
      const percentage = ((waste / mtl) * 100).toFixed(1);
      
      return {
        ot: ot.OT,
        client: ot['Razon Social'],
        total: Math.round(mtl),
        waste: Math.round(waste),
        percentage: parseFloat(percentage)
      };
    })
    .sort((a, b) => b.percentage - a.percentage)  // Worst first
    .slice(0, 5);  // Top 5
}

Waste Categories:

Acceptable: <3% (normal production variance)
Warning: 3-5% (requires investigation)
Critical: >5% (ALTO flag, immediate action)

OTD (On-Time Delivery)

Current Value: 95.8% (Last 30 days) From report-list.component.ts:92-105:

<div class="text-4xl font-black text-white tracking-tight">95.8%</div>
<p class="text-[10px] text-slate-500 mt-2 font-mono text-right">Últimos 30 días</p>

Calculation Methodology:

// Pseudo-code (actual implementation in backend)
const deliveredOnTime = orders.filter(o => 
  o.deliveryDate <= o.promisedDate && 
  o.status === 'DESPACHADO'
).length;

const totalDelivered = orders.filter(o => 
  o.status === 'DESPACHADO'
).length;

const otd = (deliveredOnTime / totalDelivered) * 100;

Industry benchmark for flexographic packaging: >95% OTD. P.FLEX currently meets this standard.

Order Status Metrics

From report-list.component.ts:225-228:

const pending = ots.filter(o => o.Estado_pedido === 'PENDIENTE').length;
const inProgress = ots.filter(o => o.Estado_pedido === 'EN PROCESO').length;
const paused = ots.filter(o => o.Estado_pedido === 'PAUSADA').length;
const completed = ots.filter(o => o.Estado_pedido === 'FINALIZADO').length;

Pendientes (Pending)

Orders awaiting production start

Scheduled but not released
Material not yet available
Machine not yet assigned

En Proceso (In Progress)

Currently in production

Material issued
Machine assigned and running
Operator actively producing

Pausadas (Paused)

Temporarily stopped

Awaiting material replenishment
Quality hold
Scheduled break or changeover

Finalizadas (Completed)

Production completed

Quality approved
Ready for packaging/shipping
Metrics finalized

Production Trend Analysis

Daily Trend Data

From report-list.component.ts:212-220:

trendData = [
  { day: 'Lun', value: 18500 },
  { day: 'Mar', value: 22400 },
  { day: 'Mié', value: 35000 },  // Peak (meets target)
  { day: 'Jue', value: 28900 },
  { day: 'Vie', value: 31200 },
  { day: 'Sáb', value: 15600 },  // Reduced shift
  { day: 'Dom', value: 8000 }    // Minimal operations
];

Target Line: 35,000 meters/day (shown as dashed line on chart) From report-list.component.ts:409-417:

const targetY = y(35000);
svg.append('line')
  .attr('x1', margin.left)
  .attr('x2', width - margin.right)
  .attr('y1', targetY)
  .attr('y2', targetY)
  .attr('stroke', 'rgba(255,255,255,0.1)')
  .attr('stroke-dasharray', '5,5');

Capacity Utilization

// Weekly production vs capacity
const weeklyProduction = trendData.reduce((sum, day) => sum + day.value, 0);
const weeklyCapacity = 35000 * 7;  // 245,000m
const utilization = (weeklyProduction / weeklyCapacity) * 100;
// = (159,500 / 245,000) * 100 = 65.1%

Interpretation
Optimization

65% Utilization:

Normal for 5-day + reduced weekend operation
Opportunity to increase weekend production if demand exists
Balance between capacity and maintenance windows

Tooling Utilization KPIs

Die Status Distribution

From inventory-die.component.ts:454-460:

get stats() {
  const total = this.dieItems.length;
  const available = this.dieItems.filter(d => d.estado === 'OK').length;
  const maintenance = this.dieItems.filter(d => 
    d.estado === 'Reparacion' || d.estado === 'Mantenimiento'
  ).length;
  const critical = this.dieItems.filter(d => 
    d.estado === 'Dañado' || d.estado === 'Desgaste'
  ).length;
  return { total, available, maintenance, critical };
}

KPIs:

Availability Rate: (available / total) * 100
Maintenance Rate: (maintenance / total) * 100
Critical Rate: (critical / total) * 100 (should be <5%)

Total Troqueles

Complete inventory count

Disponibles

Ready for immediate use

Uso Crítico

Requiring urgent attention

Quality Metrics

Incident Distribution

From quality.service.ts:52-53:

get activeIncidents() { 
  return this.incidents.filter(i => i.status !== 'Cerrada'); 
}

get closedIncidents() { 
  return this.incidents.filter(i => i.status === 'Cerrada'); 
}

KPIs:

Open Incident Rate: Active incidents / Total production orders
Mean Time to Resolution (MTTR): Average days from report to closure
Recurrence Rate: Incidents with similar root causes

CAPA Completion Rate

// Calculate CAPA effectiveness
const allActions = incidents.flatMap(i => i.actions);
const completedActions = allActions.filter(a => a.completed);
const capaCompletion = (completedActions.length / allActions.length) * 100;

// On-time completion
const onTimeActions = completedActions.filter(a => 
  new Date(a.completionDate) <= new Date(a.deadline)
);
const onTimeRate = (onTimeActions.length / completedActions.length) * 100;

Performance Benchmarks

Flexographic Industry
World-Class Targets

Industry Averages (2024):

OEE: 60-75%
Waste Rate: 4-7%
OTD: 85-92%
Changeover Time: 45-90 minutes

P.FLEX Performance:

OEE: 84.2% ✓ Above average
Waste Rate: Variable (monitor daily)
OTD: 95.8% ✓ Excellent

Export and Reporting

Excel KPI Export Structure

From report-list.component.ts:293-307:

const kpiData = [
  ['REPORTE DE INDICADORES DE PLANTA', dateStr],
  [''],
  ['METRICAS GENERALES'],
  ['Eficiencia Global (OEE)', '84.2%'],
  ['Producción Total (m)', stats.totalMeters],
  ['Tasa de Mermas (%)', stats.wastePercentage + '%'],
  ['Pedidos a Tiempo (OTD)', '95.8%'],
  [''],
  ['ESTADO DE ORDENES'],
  ['Pendientes', stats.pending],
  ['En Proceso', stats.inProgress],
  ['Finalizados', stats.completed],
  ['Pausadas', stats.paused]
];

Best Practices

Daily KPI Review

Morning Shift Meeting (15 minutes):

Review previous day’s OEE and waste
Identify top 3 waste contributors
Check for overdue CAPA actions
Set daily production target

Weekly Trend Analysis

Friday Production Review:

Export weekly Excel report
Compare against same week last month/year
Identify improvement opportunities
Update preventive maintenance schedule

Monthly Executive Summary

Export PDF Dashboard:

OEE trend vs target
Top 10 waste contributors (cumulative)
Incident closure rate
Tooling replacement forecast

Continuous Improvement

Root Cause Analysis Triggers:

OEE drops below 80% for 3+ consecutive days
Any order with >8% waste
OTD falls below 93%
More than 2 critical tooling items

Analytics Reports

Visual dashboards and trend charts

Quality Incidents

Track and resolve performance issues

Production Orders

Order-level performance data

Overview

Getting Started

Core Features

Production Modules

Inventory Management

Quality & Analytics

Administration

KPIs & Metrics

Overview

Core Production KPIs

OEE (Overall Equipment Effectiveness)

Production Volume (Linear Meters)

Waste Rate (Tasa de Mermas)

Critical Waste Identification

OTD (On-Time Delivery)

Order Status Metrics

Pendientes (Pending)

En Proceso (In Progress)

Pausadas (Paused)

Finalizadas (Completed)

Production Trend Analysis

Daily Trend Data

Capacity Utilization

Tooling Utilization KPIs

Die Status Distribution

Total Troqueles

Disponibles

Uso Crítico

Quality Metrics

Incident Distribution

CAPA Completion Rate

Performance Benchmarks

Export and Reporting

Excel KPI Export Structure

Best Practices

Analytics Reports

Quality Incidents

Production Orders

Build docs developers (and LLMs) love

Overview

Getting Started

Core Features

Production Modules

Inventory Management

Quality & Analytics

Administration

​Overview

​Core Production KPIs

​OEE (Overall Equipment Effectiveness)

​Production Volume (Linear Meters)

​Waste Rate (Tasa de Mermas)

​Critical Waste Identification

​OTD (On-Time Delivery)

​Order Status Metrics

Pendientes (Pending)

En Proceso (In Progress)

Pausadas (Paused)

Finalizadas (Completed)

​Production Trend Analysis

​Daily Trend Data

​Capacity Utilization

​Tooling Utilization KPIs

​Die Status Distribution

Total Troqueles

Disponibles

Uso Crítico

​Quality Metrics

​Incident Distribution

​CAPA Completion Rate

​Performance Benchmarks

​Export and Reporting

​Excel KPI Export Structure

​Best Practices

​Related Resources

Analytics Reports

Quality Incidents

Production Orders

Build docs developers (and LLMs) love

Overview

Core Production KPIs

OEE (Overall Equipment Effectiveness)

Production Volume (Linear Meters)

Waste Rate (Tasa de Mermas)

Critical Waste Identification

OTD (On-Time Delivery)

Order Status Metrics

Production Trend Analysis

Daily Trend Data

Capacity Utilization

Tooling Utilization KPIs

Die Status Distribution

Quality Metrics

Incident Distribution

CAPA Completion Rate

Performance Benchmarks

Export and Reporting

Excel KPI Export Structure

Best Practices

Related Resources