Table 4 Reconciliation matrix of...

Table 4

Reconciliation matrix of absolute and percentage changes

Performance metric	Baseline value (pre-lean)	Absolute shift	Mathematical derivation	Headline figure (Abstract)
Productivity	$53.9 units / hr$ 18.2 units/hour	$+ 13.0 units / hr$ +4.4 units/hour	$\frac{13.0}{53.9}$ (22.6–18.2)/18.2 × 100 = 24.18%	$+ 24.1 %$ 24.1%
Defect rate	$6.84 % (56 / 1000 units)$ 56 per 1,000	$- 3.3 % (points)$ −27 per 1,000	$\frac{3.3}{6.84}$ (56–29)/56 × 100 = 48.21%	$- 48.2 %$ 48.2%
Machine uptime	$82.3 %$ 82.3%	$+ 8.8 % (points)$ +8.8% points	$\frac{8.8}{82.3}$ (91.1–82.3)/82.3 × 100 = 10.69%	$+ 10.7 %$ 10.7%

Performance metric	Baseline value (pre-lean)	Absolute shift	Mathematical derivation	Headline figure (Abstract)
Productivity	$53.9 units / hr$ 18.2 units/hour	$+ 13.0 units / hr$ +4.4 units/hour	$\frac{13.0}{53.9}$ (22.6–18.2)/18.2 × 100 = 24.18%	$+ 24.1 %$ 24.1%
Defect rate	$6.84 % (56 / 1000 units)$ 56 per 1,000	$- 3.3 % (points)$ −27 per 1,000	$\frac{3.3}{6.84}$ (56–29)/56 × 100 = 48.21%	$- 48.2 %$ 48.2%
Machine uptime	$82.3 %$ 82.3%	$+ 8.8 % (points)$ +8.8% points	$\frac{8.8}{82.3}$ (91.1–82.3)/82.3 × 100 = 10.69%	$+ 10.7 %$ 10.7%

Note(s): The absolute downtime reduction of 28 h per month translates to an 8.8% absolute gain in actual operational runtime based on standard monthly shifts, bringing uptime from 82.3% up to 91.1%

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