The Production Stage Productivity page provides a process-level view of how work moves through the factory’s production stages.

It helps planning, production, and operations teams understand:

How much output each stage completed

How many items are currently in Work in Progress

How much physical output is held inside WIP

How much work is still waiting for each stage

Whether staffed capacity can support the current demand

Which stages are creating production bottlenecks

How much work passed successfully the first time

How much rework was processed

Where work is accumulating across the production route

Instead of reviewing individual machines or operators, Production Stage Productivity focuses on the manufacturing process.

For example, it can compare the flow through:

Bending → Rolling → Auto Welding → Fitting → Welding → Visual Inspection → Painting → Galvanizing

This helps teams identify whether one production step is limiting the flow of all downstream work.

📍 Where to Find Production Stage Productivity

Navigate to:

Productivity → Production Stages

The Productivity menu also contains:

Workstations

Labour

Users normally require the following permission:

View Workstation Productivity

This permission covers:

Workstation Productivity

Production Stage Productivity

Workstation and stage details

Andon Board

Related productivity widgets

The information displayed depends on the user’s access to the related production, scheduling, workstation, and stage records.

Production Stage Productivity Page

The Production Stage Productivity page provides access to:

Day, Week, Month, and Custom reporting periods

Output-unit selection

Stage search and bottleneck filters

Stage-level KPI cards

Stage Pipeline

Bottleneck Stage insight

Flow Strip

Individual production-stage details

All KPIs, pipeline rows, bottleneck results, and flow indicators follow the same selected:

Reporting period

Output unit

Search filter

Bottleneck-status filter

Production data

Scheduling and staffed-capacity information

How Production Stage Productivity Works

Fabritec compares each production step according to its configured route order.

The page combines:

Production-stage configuration

Item routes

Current stage buckets

Recorded production progress

Pending stage demand

Stage default durations

Workstations serving each stage

Workstation staffed capacity

Rework, revert, and refabrication activity

Item physical measurements

This allows Fabritec to compare what each stage needs to process with the capacity currently available to perform that work.

The page is designed to answer two important questions:

Where is work accumulating?

Which stage does not have enough capacity to process its demand?

Production Stage Flow

Each item follows the Production Stages defined in its assigned Route.

For example:

Cutting

Bending

Rolling

Fitting

Welding

Visual Inspection

Painting

Galvanizing

Production Stage Productivity uses this route sequence to display the stages in operational order.

This helps managers understand:

Which stages are upstream

Which stages are downstream

Where WIP is accumulating

Whether upstream production is releasing work faster than downstream stages can process it

Which stage is likely to delay the complete route

Output, Workload, and Rework

Fabritec separates successful physical output, processed workload, and corrective production.

Successful Output

Successful physical output represents completed production counted once.

When completed work is later reverted or refabricated, Fabritec prevents the same physical quantity from being counted twice as successful output.

The output credit is associated with the surviving successful production result.

Processed Workload

Processed workload represents the production attempts completed at a stage.

This preserves the actual work performed even when part of the production later requires correction.

Rework

Rework is tracked separately from normal first-pass production.

Reworked quantities:

Remain part of the stage’s real workload

Contribute to production effort

Affect Rework Percentage

Affect First-Pass Yield

Do not create duplicate successful physical output

Revert and Refabrication

When an item is reverted or refabricated back into a stage, Fabritec classifies the returning quantity as rework rather than silently treating it as new first-pass work.

The system can retain:

Revert event count

Reverted quantity

Refabricate event count

Refabricated quantity

Rework quantity

Rework hours

This makes the stage’s quality and workload history more accurate.

Company Time Zone

Production progress is grouped into reporting periods using the company time zone.

This is important when:

Production continues across midnight

Night shifts are used

Users access Fabritec from different locations

Production is recorded near the beginning or end of a reporting period

For shifts that cross midnight, production follows the scheduling rules and remains associated with the shift’s start date.

Selecting the Reporting Period

Use the period controls at the top of the page to choose the dates included in the analysis.

Available options include:

Day

Displays Production Stage Productivity for one day.

Use this view for:

Daily production meetings

Current-flow reviews

Immediate bottleneck investigation

Same-day capacity decisions

Week

Displays results for the selected week.

Use it to review:

Weekly throughput

WIP accumulation

Stage workload

Repeated bottlenecks

Weekly production-flow balance

Month

Displays results for the selected month.

Use it for:

Monthly production reviews

Capacity planning

Process-improvement analysis

Longer-term stage comparison

Custom

Allows you to select a specific start and end date.

Use a Custom period when reviewing:

A project-production window

A recovery plan

A delivery period

Performance before and after adding capacity

A specific production delay

Use the previous and next arrows to move to the equivalent preceding or following period.

Selecting the Output Unit

The output-unit selector determines how physical production is displayed.

Available options can include:

Weight

Area

Length

Volume

Pieces

Changing the selected output unit recalculates physical-output values such as:

Throughput per Day

WIP Output

Pending-Demand Output

Stage Pipeline output values

Stage-detail output values

Changing the output unit does not change item-count values such as:

WIP Items

Queue quantities

Pending-Demand Items

For example, when Weight is selected, the page may display:

WIP: 31,430 Items

WIP Output: 838.8 t

The first value counts items.

The second converts qualifying item measurements into tonnes.

Items without the physical measurement required for the selected unit are excluded from that physical-output calculation.

They are not counted as zero.

For example, an item without a weight value does not contribute to:

Weight-based throughput

WIP tonnage

Pending-demand tonnage

Active Filters

Applied filters appear below the period controls.

When no filter is active, the page displays:

No filters applied

Active filters apply to:

KPI cards

Stage Pipeline

Bottleneck Stage card

Flow Strip

Filtering Production Stages

Click Filters to open the Filter Stages window.

Available controls include:

Bottleneck Status

Clear Filters

Apply Filters

Search

Enter a Production Stage name to limit the page to matching stages.

Examples include:

Bending

Rolling

Welding

Painting

Galvanizing

Search applies to the stage cards, Stage Pipeline, and Flow Strip.

Bottleneck Status

The Bottleneck Status filter contains the following options:

All

Displays all Production Stages.

Only Bottlenecks

Displays only stages currently meeting the Fabritec bottleneck rule.

Use this option to focus immediately on stages that require capacity or planning attention.

Exclude Bottlenecks

Displays stages that are not currently marked as bottlenecks.

Use this option to compare normal-flow stages separately from overloaded stages.

Applying or Clearing Filters

Click Apply Filters to update the page.

Click Clear Filters to remove the selected filter values.

Click the X to close the window without applying additional changes.

Production Stages Button

Click Production Stages to open the Production Stage setup area.

Use this area to review or configure:

Stage names

Stage order

Default durations

Inspection requirements

Outsourcing

Linked Workstations

Linked Workstation Groups

Linked labour resources

The available actions depend on the logged-in user’s Production Setup permissions.

Stage Productivity KPI Cards

The KPI cards summarize production flow across all stages included in the current selection.

They can include:

Throughput per Day

WIP

WIP Output

Load Percentage

First-Pass Yield

Pending Demand

Pending-Demand Output

A dash, —, means Fabritec cannot calculate the value.

It does not mean zero.

Throughput per Day

Throughput per Day shows the average qualifying production completed during each day of the selected period.

The displayed unit follows the selected output unit.

Examples include:

t/day

m²/day

m/day

m³/day

pcs/day

The page presents throughput as productive output completed through the stages.

Corrective production such as rework, revert, or refabrication should not artificially increase successful physical output.

A stage can therefore show:

High WIP

High pending demand

High load

Zero throughput during the selected period

This means work exists around the stage, but no qualifying production output was completed during the selected dates.

WIP

WIP, or Work in Progress, shows the number of items currently located inside the included production-stage flow.

WIP is an item-count metric.

It answers:

How many items are currently being held or processed within the selected stages?

The WIP card remains an item count regardless of the selected output unit.

For example:

WIP: 31,430 Items

A high WIP value may indicate:

Work accumulating inside one or more stages

Slow completion

Unbalanced production flow

Insufficient capacity

Inspection holds

Rework

Excessive release of upstream work

Downstream blocking

WIP Output

WIP Output converts the current WIP items into the selected physical unit.

For example:

WIP: 31,430 Items

WIP Output: 838.8 t

This helps managers understand both:

The number of items affected

Their total physical size

Two stages may contain the same number of items but represent very different:

Weight

Area

Length

Volume

Review WIP Items and WIP Output together.

Load Percentage

Load Percentage compares the stage’s derived demand hours with its available staffed capacity.

Calculation:

Load % = Derived Demand Hours ÷ Staffed Capacity Hours × 100

Derived Demand Hours

Derived Demand Hours represent the estimated time required to process the work requiring the stage.

They depend on:

Pending quantities

Stage default durations

Item and route configuration

Current production position

Staffed Capacity Hours

Staffed Capacity Hours come from the workstations capable of performing the stage.

Capacity depends on:

Workstation calendars

Planned shifts

Operator coverage

Maintenance downtime

Workstation-stage relationships

Interpreting Stage Load

Below 85%

The stage does not meet the Fabritec bottleneck threshold.

This does not automatically mean the stage has no risk.

Also review:

WIP

Pending demand

Delivery priorities

Downstream capacity

85% or Higher

When the stage also has pending demand, Fabritec marks it as a bottleneck.

Above 100%

Demand is greater than staffed capacity for the selected period.

For example:

200% Load

means the demand represents approximately twice the staffed capacity available during the selected period.

Very High Load Percentages

The page may show very large percentages when demand is significantly higher than the available staffed capacity.

This can occur when:

A large backlog exists

Very little staffed capacity is available

Operator coverage is missing

The selected period is short compared with the complete backlog

Stage default durations are too high

Workstation-stage mappings are incomplete

Demand has accumulated over a long period

Very high percentages should trigger both:

An operational review

A configuration review

First-Pass Yield

First-Pass Yield measures how much production passed through the stage without requiring rework.

Calculation:

First-Pass Yield = 1 − (Rework-Processed Quantity ÷ Total Processed Quantity)

A high First-Pass Yield means most production completed the stage correctly on the first attempt.

A lower result may indicate:

Quality problems

Incorrect drawings or revisions

Operator training needs

Equipment instability

Incorrect process parameters

Material problems

Inspection failures

A dash means Fabritec cannot calculate the ratio from the available production quantities.

It does not mean 0%.

Pending Demand

Pending Demand shows the number of items that still require the included Production Stages.

These items have not yet completed the required production activity.

Pending Demand helps answer:

How much future work is waiting?

Which stage will receive the greatest workload?

Where should capacity be added?

Which stage may delay downstream delivery?

Pending Demand is an item-count value.

Changing the output unit does not change the number of pending items.

Pending-Demand Output

Pending-Demand Output converts the pending item quantity into the selected physical unit.

For example:

Pending Demand: 94,279 Items

Pending-Demand Output: 2,640.3 t

This provides a clearer workload picture than item count alone.

A stage may have:

Many small items

Fewer heavy items

A large area but low item count

A large quantity with low processing effort

Review both item count and physical output before making a capacity decision.

Understanding a Dash

Fabritec displays — when a value cannot be calculated.

Possible reasons include:

No staffed-capacity denominator

No qualifying production

Missing physical measurements

Missing stage default durations

No linked Workstations

No resolved workstation shifts

No processed or rework quantities

The current filters exclude the required records

A dash does not mean zero.

Zero

A displayed zero means Fabritec calculated a genuine zero result.

Example:

Throughput: 0 t

Dash

A dash means the required calculation cannot be completed.

Example:

First-Pass Yield: —

Stage Pipeline

The Stage Pipeline provides one row for each Production Stage in route order.

It is the main comparison table for the complete production process.

The table can include:

Column	Function
Route Order	Position of the stage in the configured production sequence
Stage	Stage name and bottleneck status
Throughput per Day	Average qualifying production completed per day
WIP	Items currently in progress at the stage
WIP Output	Physical output represented by the stage’s WIP
Queue Depth	Current quantity held in or waiting around the stage
Load %	Demand hours compared with staffed capacity
First-Pass Yield	Production completed without rework
Rework %	Share of processed production classified as rework
Pending Demand	Items that still require the stage
Pending-Demand Output	Physical quantity still requiring the stage

Additional columns may be available by scrolling horizontally.

Route Order

Route Order displays the configured operational sequence.

Example:

Bending

Rolling

Auto Welding

Fitting

Welding

Visual

Painting

Galvanizing

The route order helps users understand where a stage sits in relation to upstream and downstream processes.

Route order is based on Production Setup.

It is not determined by the current load.

Stage Name

The Stage column displays the Production Stage name.

Examples include:

Bending

Rolling

Auto Welding

Fitting

Welding

Visual

Painting

Galvanizing

Cold Forming

Laser Cutting

Use clear and consistent stage names in Production Setup.

Duplicate or inconsistent stages can divide demand and make the pipeline difficult to interpret.

Bottleneck Label

Stages meeting the bottleneck rule display:

Warning icon

Bottleneck label

Highlighted load indicator

Fabritec uses icon, text, and color so the status does not depend on color alone.

Several stages can be marked as bottlenecks at the same time.

Queue Depth

Queue Depth shows the current quantity located within or waiting around the stage’s live processing queue.

Use it to understand how deep the work accumulation has become.

A high Queue Depth can indicate:

Work released faster than the stage can process it

Insufficient workstation capacity

Missing operator coverage

Downstream blocking

Large production batches

Extended quality holds

Rework accumulation

Queue Depth should be reviewed with:

WIP

Pending Demand

Load Percentage

Throughput

Rework Percentage

Rework Percentage measures the share of processed stage quantity classified as rework.

Calculation:

Rework % = Rework-Processed Quantity ÷ Total Processed Quantity × 100

Rework still contributes to production effort.

It is not removed from the amount of work the stage performed.

A dash means the required processed-quantity denominator is unavailable.

Bottleneck Rules

Fabritec marks a Production Stage as a bottleneck when:

The stage has pending demand.

Its demand load is at least 85% of staffed capacity.

This rule is applied to every included stage.

More than one stage can be marked as a bottleneck.

For example:

Bending: 90%

Rolling: 150%

Welding: 300%

All three stages qualify as bottlenecks because they have pending demand and at least 85% load.

Bottleneck Stage Card

The Bottleneck Stage card highlights one primary bottleneck.

Fabritec selects the highest-load stage among the stages meeting the bottleneck rule.

The card displays:

Stage name

Load Percentage

WIP

View Details action

For example:

Welding

Load: 201,590%

WIP: 1,077

Click View Details to investigate the stage.

Why Only One Stage Appears on the Card

The Stage Pipeline may show several bottlenecks.

The Bottleneck Stage card displays only the qualifying stage with the highest load.

For example:

Bending: Bottleneck

Rolling: Bottleneck

Welding: Bottleneck

Painting: Bottleneck

Cold Forming: Bottleneck

When Welding has the highest load, Welding appears on the Bottleneck Stage card.

All other qualifying stages remain marked as Bottlenecks in the Stage Pipeline and Flow Strip.

No Bottleneck Stage

When no stage has both:

Pending demand

At least 85% load

Fabritec does not identify a Bottleneck Stage.

This does not guarantee that the production flow has no risk.

Also review:

WIP growth

Pending-demand output

Quality

Missing capacity configuration

Stages approaching the threshold

Flow Strip

The Flow Strip provides a compact view of load across the complete production route.

Each stage card can display:

Stage name

Load indicator

Load Percentage

Bottleneck highlighting

The Flow Strip helps managers see where production pressure exists without reviewing every Pipeline column.

Reading the Flow Strip

A normal stage can display:

Neutral background

Small load indicator

Low or zero load

A bottleneck stage displays:

Highlighted background

Warning treatment

Stronger load indicator

High Load Percentage

The stages follow the configured route order.

In Arabic, the route presentation mirrors for right-to-left reading.

Stage with 0% Load

A stage may show 0% load when:

No derived demand hours exist

No applicable pending demand exists

Pending items have no valid default duration

Current filters exclude its work

Demand cannot be translated into hours

Review a zero-load stage together with Pending Demand.

A stage with pending items but zero load may indicate missing duration configuration.

Opening Production Stage Details

To open an individual stage:

Navigate to Productivity → Production Stages.

Locate the stage in the Stage Pipeline or Bottleneck Stage card.

Click the stage or View Details.

The Production Stage Detail page provides a deeper analysis of one process step.

It can include:

Stage header and bottleneck status

Stage KPI cards

Cumulative Flow Diagram

Throughput trend

WIP trend

Cycle-time distribution

Rework and quality results

Revert and refabricate flows

Contributing Workstations

Contributing labour resources

Click Back to Overview to return to Production Stage Productivity.

Production Stage Detail Header

The header can display:

Production Stage name

Route position

Bottleneck status

Load Percentage

Reporting period

Output unit

Back to Overview action

Use the header to confirm that the correct stage, period, and output unit are being reviewed.

Production Stage Detail KPI Cards

The stage-detail KPI strip can include:

Throughput

WIP

Average Cycle Time

First-Pass Yield

Rework Percentage

Rework Hours

Load Percentage

Throughput

Shows the qualifying production completed at the selected stage during the selected period.

WIP

Shows the items currently located within the stage’s active production buckets.

Average Cycle Time

Average Cycle Time measures how long work takes to move through the stage.

Conceptually:

Cycle Time = Time the item leaves the stage − Time the item enters the stage

Fabritec uses the available production-progress timestamps.

When complete entry and exit timestamps are unavailable, the page may use an estimated relationship based on WIP and throughput.

Any estimated value should be identified as an estimate.

First-Pass Yield

Shows the percentage of processed stage production completed without rework.

Rework Percentage

Shows the share of processed stage quantity classified as rework.

Rework Hours

Rework Hours show the production time attributed to rework at the selected stage.

For a record containing both first-pass and rework quantity, Fabritec can attribute the proportional rework share of the operation’s duration.

Conceptually:

Rework Hours = Operation Duration × Rework Quantity Share

The complete recorded duration still remains part of total production effort.

Rework-hour attribution does not reduce the stage’s actual work duration.

Load Percentage

Shows derived stage demand compared with staffed capacity.

Cumulative Flow Diagram

The Cumulative Flow Diagram, or CFD, shows how work arrives at and departs from the Production Stage over time.

It helps users understand:

Work entering the stage

Work leaving the stage

Changes in WIP

Changes in flow rate

Growing queues

Possible lead-time increases

Reading the Cumulative Flow Diagram

The diagram compares cumulative arrivals and departures.

Band Width

The width between arrivals and departures represents WIP.

A growing band can indicate:

Arrivals are increasing faster than completions

WIP is accumulating

Stage capacity is insufficient

Production has slowed

Horizontal Distance

The horizontal difference between arrival and departure curves provides cycle-time or lead-time context.

A widening distance may indicate that work is taking longer to pass through the stage.

Throughput and WIP Trends

The stage-detail page can include separate trends for:

Throughput

WIP

Use them together to understand the stage condition.

Increasing Throughput with Stable WIP

The stage may be processing demand successfully.

Low Throughput with Increasing WIP

The stage may be becoming constrained.

High Throughput with Increasing WIP

Incoming work may still be arriving faster than the stage can complete it.

Falling WIP

The stage may be recovering or completing backlog faster than new work arrives.

Cycle-Time Distribution

The Cycle-Time chart shows how long different items took to complete the stage.

It can display:

Cycle-time ranges

Number of items in each range

Average Cycle Time

Long-duration outliers

Use the distribution rather than relying only on the average.

For example, the average may appear acceptable while a small number of items remain in the stage for an unusually long time.

Possible causes include:

Material shortages

Quality holds

Large or complex items

Workstation breakdown

Missing operator coverage

Production-recording delays

Revert and Refabricate Flows

The Stage Detail page can show corrective-production flows connected to the stage.

It can include:

Number of Revert actions

Reverted quantity

Number of Refabricate actions

Refabricated quantity

Source or destination stage

Rework quantity

Rework hours

Revert

A Revert returns production to an earlier stage for correction.

The reverted quantity is treated as rework when it re-enters the affected stage.

Refabricate

Refabrication means production must be produced again according to the applicable workflow.

The refabricated quantity remains part of the stage’s corrective workload.

Why Reverts and Refabricates Are Shown Separately

Rework Percentage explains the quantity affected by corrective production.

Revert and Refabricate counts explain how often corrective actions occurred.

For example:

One Revert event may affect 100 items.

Ten Revert events may affect only 10 items.

Both event count and quantity are operationally important.

Resource Breakdown

The Resource Breakdown identifies the Workstations and labour resources performing the selected stage.

It can include:

Workstation name

Workstation group

Machine-hours

Output

Utilization

Hours per unit

Labour name or crew

Man-hours

Output share

Efficiency

Use this section to understand whether stage performance is concentrated around:

One workstation

One workstation group

One crew

A small number of operators

Where permitted, resource names can link to:

Workstation Productivity

Workstation Details

Labour Productivity

Individual Labour Details

Understanding the Submitted Example

The submitted Production Stage Productivity page shows:

Throughput per Day: 0 t

WIP: 31,430 Items

WIP Output: 838.8 t

Load: 122,088%

First-Pass Yield: —

Pending Demand: 94,279 Items

Pending-Demand Output: 2,640.3 t

This indicates that:

A significant quantity of work is currently inside the production-stage flow.

A much larger quantity still requires future stages.

The derived demand is significantly greater than the staffed capacity available in the selected week.

No qualifying throughput was recorded during the selected period.

The available production information is not sufficient to calculate First-Pass Yield.

The production team should review:

Whether production progress is being recorded

Whether the selected period is correct

Whether Workstations have planned and staffed shifts

Whether stage default durations are realistic

Whether Workstations are linked to the correct stages

Whether pending demand contains duplicated or incorrect routes

Whether backlog has accumulated faster than the factory can process it

Implementing Production Stage Productivity

Reliable Production Stage Productivity depends on accurate Production Stages, Routes, durations, Workstations, schedules, item measurements, and production records.

Follow this implementation sequence.

1. Grant the Required Permission

Grant authorized users:

View Workstation Productivity

Typical authorized users include:

Production Managers

Operations Managers

Production Planners

Production Supervisors

Factory Managers

Continuous-Improvement Teams

2. Configure Production Stages

Navigate to:

Production Setup → Production Stages

Create the real manufacturing steps used in the factory.

Examples include:

Cutting

Bending

Rolling

Fitting

Welding

Visual Inspection

Painting

Galvanizing

Every stage should represent a real operational step that can be:

Planned

Performed

Recorded

Measured

Reported

3. Use Clear and Consistent Stage Names

Avoid creating duplicate or overlapping stages such as:

Cutting

cutting

Cutting Area

Laser Cutting

القطع

unless they represent genuinely different production operations.

Duplicate stages can divide:

WIP

Pending demand

Workstation capacity

Throughput

Rework

Load

This can make the Stage Pipeline difficult to interpret.

4. Configure Stage Order

Arrange Production Stages in the organization’s main operational sequence.

After changing the order:

Drag the stages into the required position.

Click Save Order.

The Save Order button becomes active after at least one stage has been moved.

The Pipeline and Flow Strip use stage order to present the manufacturing process.

Individual Routes can still contain their own required stages and sequence.

5. Configure Routes

Create production Routes that reflect how different items are actually manufactured.

Example:

Cutting

Bending

Fitting

Welding

Painting

Make sure each item is assigned to the correct Route.

An item should not create demand for a stage it does not require.

Incorrect Route assignments can inflate:

Pending Demand

Queue Depth

Derived Demand Hours

Load Percentage

6. Configure Stage Default Durations

Enter realistic Default Durations for the Production Stages.

Examples include:

Production Stage	Example Default Duration
Auto Welding	00:10
Fitting	00:40
Bending	01:00
Rolling	02:00
Welding	03:00

Default Durations support:

Derived demand hours

Stage load

Machine Load

Efficiency standards

Capacity planning

When durations are missing:

Pending item counts may still appear

Demand hours may be incomplete

Load may show zero or a dash

Bottleneck identification may be unreliable

Review Default Durations regularly against actual production results.

7. Link Workstations to Production Stages

Configure the Workstations capable of performing each stage.

Example:

Bending

Angle Bending Machine

Pipe Bending Machine

Rolling

Plate Rolling Machine

Welding

MIG/MAG Welding Station

Automatic Welding Machine

Stage capacity depends on the Workstations serving the stage.

A stage with demand but no linked Workstation cannot provide a reliable capacity comparison.

8. Configure Workstation Groups

Use Workstation Groups when several related Workstations share the same production function.

Review whether the stage relationship comes from:

Direct Workstation assignment

Workstation Group assignment

Make sure Workstations are not unintentionally linked to the wrong stage.

9. Configure Workstation Capacity

For each Workstation serving the stage, confirm:

Capacity type

Capacity quantity

Capacity unit

Workstation type

Stream type

Operational status

Examples include:

Tonnes per hour

Pieces per hour

Square metres per hour

Metres per hour

Capacity configuration supports stage demand and performance analysis.

10. Configure Work Calendars and Shifts

Assign the correct:

Work calendar

Working days

Non-working days

Shift

Shift start time

Shift end time

Schedule exceptions

Stage staffed capacity depends on the schedules of the Workstations serving it.

11. Assign Operators

Assign qualified operators to the Workstations and shifts serving each stage.

A Workstation may have planned hours but contribute no staffed capacity when no present operator is resolved.

Missing operator coverage can cause a stage’s Load Percentage to rise significantly.

12. Link Labour Resources

Link eligible labour resources to the Production Stages they can perform.

This supports:

Operator planning

Stage-resource visibility

Workstation staffing

Labour and stage productivity analysis

Stage-labour links do not replace daily operator and shift assignments.

13. Complete Item Physical Measurements

Make sure production items contain the measurements used for reporting.

Depending on the selected output unit, complete:

Weight

Area

Length

Volume

Quantity

Items without the selected physical measurement cannot contribute to:

Throughput output

WIP Output

Pending-Demand Output

14. Release Production Work Correctly

Use the project and production workflows to release items into the correct production Routes.

Stage Productivity relies on each item’s current operational position.

Incorrect release or route status can cause items to:

Appear in the wrong stage

Remain in Pending Demand

Remain indefinitely in WIP

Create incorrect load

15. Record Production Progress

Operators and supervisors should record:

Correct Production Stage

Correct Workstation

Correct item or mark

Processed quantity

Successful quantity

Operation duration

Labour users

Completion status

Rework quantity where applicable

Without production progress:

Throughput remains zero

WIP can continue accumulating

Pending Demand remains high

First-Pass Yield cannot be calculated

Cycle Time may be unavailable

16. Record Rework, Reverts, and Refabrication

Use the correct Production and Quality Control actions for:

Rework

Revert

Refabrication

Correct classification supports:

Rework Percentage

Rework Hours

First-Pass Yield

Revert counts

Refabricate counts

Corrective-flow analysis

Corrective work must not be recorded as new first-pass production.

17. Validate Production Stage Productivity

Navigate to:

Productivity → Production Stages

Then:

Select the reporting period.

Select the required output unit.

Review Throughput per Day.

Review WIP and WIP Output.

Review Pending Demand and Pending-Demand Output.

Review Load Percentage.

Review First-Pass Yield.

Check the Stage Pipeline.

Identify all stages marked as Bottlenecks.

10.

Review the primary Bottleneck Stage card.

11.

Compare the stages in the Flow Strip.

12.

Apply Only Bottlenecks.

13.

Investigate stages with zero load and pending demand.

14.

Investigate unusually high Load Percentages.

15.

Open the primary stage’s details.

16.

Review cycle time, rework, and contributing resources.

Complete Operational Example

A factory uses the following Route:

Bending → Rolling → Fitting → Welding → Painting

During the selected week, Fabritec calculates:

Stage	Pending Demand	Demand Hours	Staffed Capacity	Load
Bending	300 Items	90 h	100 h	90%
Rolling	250 Items	150 h	100 h	150%
Fitting	100 Items	40 h	120 h	33%
Welding	500 Items	300 h	100 h	300%
Painting	80 Items	50 h	100 h	50%

Fabritec identifies:

Bending as a Bottleneck because it has pending demand and 90% load.

Rolling as a Bottleneck because it has pending demand and 150% load.

Welding as a Bottleneck because it has pending demand and 300% load.

Welding as the primary Bottleneck Stage because it has the highest qualifying load.

Management can then consider:

Assigning more welders

Adding a Welding shift

Moving work to another Welding Workstation

Rescheduling lower-priority work

Reducing upstream release

Reviewing Welding default durations

Investigating workstation downtime

Reviewing operator coverage

The purpose is not only to identify the overloaded stage.

It is also to control how upstream and downstream production should respond.

Recommended Daily Workflow

During the Daily Production Meeting

Open Production Stage Productivity.

Select Day or Week.

Review the Bottleneck Stage card.

Filter to Only Bottlenecks.

Compare WIP, Pending Demand, and Load.

Confirm whether the constrained stage has operator coverage.

Review the related Workstations.

Adjust production priorities or capacity.

Control upstream work release.

10.

Confirm the corrective action with supervisors.

During Weekly Planning

Review Throughput per Day.

Compare the complete Stage Pipeline.

Identify stages accumulating WIP.

Review stages with high Pending-Demand Output.

Check duration and capacity assumptions.

Review Workstation shifts.

Review operator assignments.

Adjust the production plan.

Rebalance work across capable Workstations.

During Monthly Review

Use Production Stage Productivity to evaluate:

Persistent bottlenecks

Stage-capacity shortages

WIP accumulation

Throughput changes

Quality and rework

Cycle-time performance

Need for additional Workstations

Need for additional labour

Shift redesign

Route redesign

Process-improvement opportunities

Common Conditions and Their Meaning

Throughput Is Zero but WIP Is High

Items are currently inside the production flow, but no qualifying output was completed during the selected period.

Review:

Production recording

Stage completion

Selected dates

Quality holds

Workstation availability

Pending Demand Is High but Load Is Zero

Pending quantities exist, but Fabritec may not have the duration information required to convert them into demand hours.

Review Stage Default Duration.

Load Is Extremely High

Demand hours are significantly greater than staffed capacity.

Review:

Backlog

Default Durations

Workstation shifts

Operator coverage

Workstation-stage mapping

Selected reporting period

Several Stages Are Bottlenecks

Each stage independently has:

Pending demand

At least 85% load

The summary card still displays only the stage with the highest load.

First-Pass Yield Displays a Dash

Processed and rework quantities required for the ratio are unavailable.

Rework Percentage Displays a Dash

Fabritec cannot calculate the ratio from the current production records.

WIP Items Have a Value but WIP Output Is Zero

The WIP items may not contain the physical measurement required for the selected output unit.

Pending Demand Has Items but No Output Value

The pending items may not contain the selected physical measurement.

A Stage Has Pending Demand but No WIP

Items still require the stage but have not yet entered active processing at that stage.

A Stage Has WIP but Little Pending Demand

Most of the stage’s current work has already entered processing, but completion may be slow.

A Stage Has 0% Load and Pending Demand

Review whether:

Default Duration is missing

Staffed capacity is missing

The items are assigned to the correct Route

Demand hours can be derived

Duplicate Stage Names Appear

Production Setup may contain separate or duplicated Production Stage records.

Review whether they should be consolidated.

Stage Load Changes When the Period Changes

Pending demand can remain the same while the capacity denominator changes.

For example, the same backlog compared with:

One day of capacity

One week of capacity

One month of capacity

produces different Load Percentages.

A Dash Appears Instead of Infinity

The required denominator is zero or unavailable.

Fabritec displays a not-available state rather than dividing by zero.

Governance Rules

Users require the appropriate Workstation Productivity permission.

Every Production Stage must have a clear operational purpose.

Stage names should remain consistent across the organization.

Duplicate stages should be avoided.

Stages should be arranged in the correct operational order.

Route configuration should reflect actual manufacturing requirements.

Stage Default Durations should be realistic.

Every internal production stage should have applicable Workstations.

Workstations should be linked to the correct stage.

Work calendars and shifts should remain current.

Staffed capacity requires present operators.

Item physical measurements should be completed.

Production progress must be recorded against the correct stage.

Rework must be classified separately from first-pass production.

Revert and Refabricate activity must remain visible.

A dash must not be interpreted as zero.

Very high Load Percentages should trigger setup and operational reviews.

Current-period information should be treated as in progress.

Bottleneck decisions should consider WIP, demand, capacity, and delivery priorities together.

Production Stage Productivity should be used to manage flow, not only to rank stages.

⭐ Best Practices

Use clear and recognizable Production Stage names.

Keep the general stage order aligned with the factory workflow.

Assign items to the correct Routes.

Avoid releasing more work than constrained stages can absorb.

Configure realistic Default Durations.

Review actual cycle times and update standards when necessary.

Link every stage to the correct Workstations.

Keep Workstation shifts and operator assignments current.

Complete item Weight, Area, Length, Volume, and Quantity data.

Record production progress at the correct stage.

Record Rework, Reverts, and Refabrication accurately.

Review Load Percentage with WIP and Pending Demand.

Investigate zero-load stages that still have pending work.

Investigate very high loads before adding permanent capacity.

Use Only Bottlenecks during daily production meetings.

Use the Flow Strip for a quick management view.

Use the Stage Pipeline for detailed investigation.

Open Stage Details before deciding on corrective action.

Review cycle-time distributions rather than relying only on averages.

Compare contributing Workstations before purchasing new equipment.

Review labour coverage before increasing planned capacity.

Compare several periods before making long-term capacity decisions.

Dashboards – Visual productivity analytics

Production – Track production items and progress

Shipping – Manage shipping lists & readiness

Shifts – Optimize workforce allocation

Production Stage Productivity

Production Stage Productivity Page#

How Production Stage Productivity Works#

Production Stage Flow#

Output, Workload, and Rework#

Successful Output#

Processed Workload#

Rework#

Revert and Refabrication#

Company Time Zone#

Selecting the Reporting Period#

Day#

Week#

Month#

Custom#

Selecting the Output Unit#

Active Filters#

Filtering Production Stages#

Search#

Bottleneck Status#

All#

Only Bottlenecks#

Exclude Bottlenecks#

Applying or Clearing Filters#

Production Stages Button#

Stage Productivity KPI Cards#

Throughput per Day#

WIP#

WIP Output#

Load Percentage#

Derived Demand Hours#

Staffed Capacity Hours#

Interpreting Stage Load#

Below 85%#

85% or Higher#

Above 100%#

Very High Load Percentages#

First-Pass Yield#

Pending Demand#

Pending-Demand Output#

Understanding a Dash#

Zero#

Dash#

Stage Pipeline#

Route Order#

Stage Name#

Bottleneck Label#

Queue Depth#

Rework Percentage#

Bottleneck Rules#

Bottleneck Stage Card#

Why Only One Stage Appears on the Card#

No Bottleneck Stage#

Flow Strip#

Reading the Flow Strip#

Stage with 0% Load#

Opening Production Stage Details#

Production Stage Detail Header#

Production Stage Detail KPI Cards#

Throughput#

WIP#

Average Cycle Time#

First-Pass Yield#

Rework Percentage#

Rework Hours#

Load Percentage#

Cumulative Flow Diagram#

Reading the Cumulative Flow Diagram#

Band Width#

Horizontal Distance#

Throughput and WIP Trends#

Increasing Throughput with Stable WIP#

Low Throughput with Increasing WIP#

High Throughput with Increasing WIP#

Falling WIP#

Cycle-Time Distribution#

Revert and Refabricate Flows#

Revert#

Refabricate#

Why Reverts and Refabricates Are Shown Separately#

Production Stage Productivity Page

How Production Stage Productivity Works

Production Stage Flow

Output, Workload, and Rework

Successful Output

Processed Workload

Rework

Revert and Refabrication

Company Time Zone

Selecting the Reporting Period

Day

Week

Month

Custom

Selecting the Output Unit

Active Filters

Filtering Production Stages

Search

Bottleneck Status

All

Only Bottlenecks

Exclude Bottlenecks

Applying or Clearing Filters

Production Stages Button

Stage Productivity KPI Cards

Throughput per Day

WIP

WIP Output

Load Percentage

Derived Demand Hours

Staffed Capacity Hours

Interpreting Stage Load

Below 85%

85% or Higher

Above 100%

Very High Load Percentages

First-Pass Yield

Pending Demand

Pending-Demand Output

Understanding a Dash

Zero

Dash

Stage Pipeline

Route Order

Stage Name

Bottleneck Label

Queue Depth

Rework Percentage

Bottleneck Rules

Bottleneck Stage Card

Why Only One Stage Appears on the Card

No Bottleneck Stage

Flow Strip

Reading the Flow Strip

Stage with 0% Load

Opening Production Stage Details

Production Stage Detail Header

Production Stage Detail KPI Cards

Throughput

WIP

Average Cycle Time

First-Pass Yield

Rework Percentage

Rework Hours

Load Percentage

Cumulative Flow Diagram

Reading the Cumulative Flow Diagram

Band Width

Horizontal Distance

Throughput and WIP Trends

Increasing Throughput with Stable WIP

Low Throughput with Increasing WIP

High Throughput with Increasing WIP

Falling WIP

Cycle-Time Distribution

Revert and Refabricate Flows

Revert

Refabricate

Why Reverts and Refabricates Are Shown Separately

Resource Breakdown