This is an illustrative pattern, based on how garment floors are generally run. It is not any particular client project.
Hourly output on the line board, copied into a register, then typed into Excel after the shift. Every morning management looks at yesterday. This is how most floors are running when we are called.
What we checked first
We did not talk about software first. We sat on one floor for a full shift and saw how long a stoppage takes to reach the office as a number. The gap we usually find is close to a full shift, between a line stopping and the office seeing it. The supervisor knows within a minute; there is just no way for him to pass it on.
Nobody is hiding anything. The record is just kept in three places.
What we built
A production board fed from the floor, with hourly output, efficiency and DHU for each line, and a stoppage alert that reaches the office while the line is still down.
How it rolled out
Four lines first, for one month, keeping the boards and registers as they are. After that, the rest of the floor.
Where it stands
The office sees the shift while it is running, a stoppage is handled in minutes, and the monthly report comes from the same data the floor already entered.
Yesterday's output reviewed today
The shift seen as it runs
A stoppage reported at day end
Answered in minutes
Efficiency calculated next morning
Calculated per hour