Process Cycle Time & Throughput Optimization

Revenue/Prod Hr

$4,218

+8.2%

Bottleneck P90

8.4 min

+16.7%

Throughput Yield

126 u/hr

+5.0%

WIP Queue (St3)

47 units

Target: 20

First-Time Through

94.3%

+1.8%

Avg Changeover

18.2 min

-12.5%

Process Flow with WIP Queue Indicators

Stage 1

Material Prep · 126 u/hr

12 WIP

Stage 2

Rough Machine · 128 u/hr

18 WIP

Stage 3

CNC Bore · 119 u/hr

47 WIP

Stage 4

Thread Cut · 135 u/hr

22 WIP

Stage 5

Finish & Polish · 132 u/hr

15 WIP

Stage 6

Inspection · 140 u/hr

8 WIP

Stage 7

Packaging · 145 u/hr

5 WIP

Constraint Identified: Stage 3 (CNC Bore) — P90 cycle time 8.4 min vs. 7.2 min baseline. WIP queue 47 units (2.35× buffer target).

Cycle Time Distribution by Stage

Box: P25–P75 | Whiskers: Min–Max | Line: P50 Median | Red: P90

Stage Utilization Breakdown

Green: Productive | Yellow: Changeover | Red: Idle/Waiting

Throughput Yield & WIP Level — Weekly Dual Axis

Stage Cycle Time CV — Variability Index

CV = StdDev/Mean · Higher CV indicates process instability

FTT Rate by Product Family

Process Stage Performance Matrix

Stage	P50 Cycle (min)	P90 Cycle (min)	WIP Queue	Utilization	FTT Rate	CV
Stage 1: Material Prep	3.2	4.1	12	82%	98.2%	0.18
Stage 2: Rough Machine	4.1	5.3	18	78%	96.8%	0.22
Stage 3: CNC Bore ⚠	6.8	8.4	47	91%	95.1%	0.31
Stage 4: Thread Cut	3.8	4.9	22	74%	97.3%	0.21
Stage 5: Finish & Polish	4.5	5.7	15	76%	93.8%	0.24
Stage 6: Inspection	2.9	3.6	8	71%	94.3%	0.19
Stage 7: Packaging	2.4	3.1	5	69%	99.1%	0.16