The daily total showed a gap, but not its cause.
The team wanted more output from each production day. The line was losing time before and during production: raw material was not always ready, big bins were unavailable, and short stops interrupted the run. A kilogram total could show underperformance without explaining where the day had gone.
Material and bins were stopping the day.
The losses were specific: raw material not ready, big bins unavailable and insufficient bins on the line. Neuron linked those reasons to kilograms produced on the same day, showing material, planning and production where preparation was affecting output.
The team improved material preparation and bin readiness, reduced changeover delays and cleared short stops. Material-not-ready, big-bin and insufficient-bin losses all read zero in Month 3.
A stronger production day.
Output reached 10,181 kg per production day in Month 3. Effectiveness reached 87.4%, above the 85% goal. Month 2 had the highest output; Month 3 remained above the starting level. The line reported ₹3 lakh in additional daily revenue.
The comparison behind the result.
| Measure | Month 1 | Month 2 | Month 3 |
|---|---|---|---|
| Output / production day | 7,852 kg | 10,860 kg | 10,181 kg |
| Unplanned time / production day | 80 min | 53 min | 44.5 min |
| Effectiveness | 83.8% | 89.2% | 87.4% |
Three-month operating report for the measured candy production line. Output and unplanned time are per production day. Revenue is additional revenue from those operations.
Read the full case study PDF