TBM Consulting Group

Operational Excellence One Point Lesson

Hour-by-Hour Chart Consistency

Category: Tools Business: General Application Lesson: 35 Author: Ken Van Winkle

PROBLEM OR OPPORTUNITY
Fundamental to the lean principle of pacing to takt time is ensuring that the line/work cell is
achieving its output targets each and every hour of the day/shift. As obvious as this may seem,
many environments find it difficult to consistently use the Hour-by-Hour Chart to ensure that they
pace to takt, and then resolve abnormalities that prevent pacing to takt time.

COUNTERMEASURE
Most importantly, make sure that the Hour-by-Hour Chart is a requirement for each line/work
cell, both on the shop floor and in the support/office areas.
All should use a consistent format and the targets should ensure that all departments are
aligned to pacing to takt time.
It should be very clear as to who the owner of the Hour-by-Hour Chart is (usually the front
line supervisor).
Owners should be trained and certified in understanding and using the Hour-by-Hour Chart
including things such as how to calculate the hourly targets, how to post the numbers and
calculate any variances and when comments (abnormalities/flow interrupters) are required to
be documented on the chart.
A robust problem solving process is required to ensure that abnormalities/flow interrupters
can be dealt with and resolved.
Finally, the KPO (or another suitable leader) should audit the charts on a regular basis to
ensure proper use.

RESULTS
All departments will be aligned to the common goal of meeting customer demand (takt
time). Problems (abnormalities/flow interrupters) will be quickly identified with the
expectation that a resolution be implemented as priority 1.

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TBM Consulting Group, Inc. 4400 Ben Franklin Blvd., Durham, NC 27704 P: 800.438.5535 www.tbmcg.com

WorkCell:
TIME
3AM4AM
4AM5AM
5AM6AM
6AM7AM
7AM8AM
8AM9AM
9AM10AM
10AM11AM
11AM12PM
12PM1PM
1PM2PM
2PM3PM
3PM4PM
4PM5PM
5PM6PM
6PM7PM
7PM8PM
8PM9PM
9PM10PM
10PM11PM
11PM12AM
12AM1AM
1AM2AM

TARGET
50
45
50
50
25

CUMULATIVE
ACTUAL VARIANCE

HOURBYHOURCHART
Date:
BYTHEHOUR
ACTUAL VARIANCE
TARGET
50
95
145
195
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220

COMMENTS

HOURBYHOURCHARTINSTRUCTIONS
1.Populate"ByTheHour"targetsinBLACK ink,asfollows:
HourWhichIncludes.
StartUp(5min)
Break,stretch(20min)
Lunch,frock(33min)
5S(8min)
Allfullhoursofproduction

SecAvailable Day(TT477) Swing(TT885)

3300
7
4
2400
5
3
1620
3
2
3120
7
4
3600
8
4

2.Populate"Cumulative"targetsinBLACK ink.
a.Copythefirsthour'stargetnumberintothefirstCumulativetarget.
BYTHEHOUR
TARGET
5

ACTUAL

VARIANCE

TARGET
5

CUMULATIVE
ACTUAL

VARIANCE

b.Addthenexthour'starget#tothepriorCumulativetarget.ThisistheNEW
Cumulativetarget.
BYTHEHOUR
TARGET
5
6

ACTUAL

VARIANCE

TARGET
5
11

CUMULATIVE
ACTUAL

VARIANCE

5+ 6=11
c.ContinueaddingthenumbersuntilallCumulativetargetsarefilledin.
3.Attheendofeachhour,fillintheActualandcalculatetheVariance(TargetActual=Variance).
IftheVarianceisZeroorapositivenumber,filloutinGREEN.IftheVarianceisanegativenumber,
filloutinRED.
BYTHEHOUR
TARGET
5
6

ACTUAL
6
3

VARIANCE
+1
3

TARGET
5
11

CUMULATIVE
ACTUAL
6
9

6+ 3=9
4.Attheendofeachhour,fillintheCommentssectionwiththenumberofrejects,and
specificreasonsforwhythevariancewaspositiveornegative.
5.Foranyissue/commentthatresultedinmissingthetargetforthehour,doarootcause
analysisandensurethattheissueisresolvedASAP.(Gatheradditionalsupportresources
asneeded.)

VARIANCE
+1
2