KPI & Capacity Analysis

A KPI needs a decision and an owner

Each measure needs a definition, formula, unit, source, cutoff, exclusions, owner, review frequency, and action threshold. Keep the numerator and denominator, distinguish missing data from zero, and reconcile reports before interpreting trends.

Measures matched to the process

• Flow: dock-to-stock, putaway cycle time, order or transfer cycle time, trailer and lane dwell
• Inventory: inventory accuracy, location accuracy, exception rate, rework, and touches per unit
• Workload: units per labor hour, backlog aging, and schedule attainment
• Equipment: utilization, availability, productive uptime, charging downtime, and maintenance downtime

Equipment and capacity analysis

Review forklift and lift demand by shift and peak window. Separate productive time, idle time, travel, charging, and maintenance. Compare battery runtime, charger constraints, workload, and fleet availability before drawing a fleet-sizing conclusion. An average utilization percentage can conceal a peak constraint.

Useful outputs

• Metric dictionary and reporting ownership
• Baseline and data-quality assessment
• Workload, lift-fleet, and charging-demand profile
• Capacity constraints and options with stated assumptions
• Pilot measurement and review plan

Interpret within the evidence

Findings depend on the sample, definitions, product mix, staffing, and demand conditions. Proposed changes are intended to improve control and must be validated. Coleman Efficiency does not provide a specialized engineering certification or guarantee a capacity or savings result.

Plan the work before committing

Who needs to be involved. The manager who will use the analysis, a process owner and someone who understands how the source records are created. Include an authorized technical specialist where equipment or systems questions require one.

What to prepare. The decision to be supported, current metric definitions, an agreed period of source records, and relevant shift, workload or equipment context. We first check what the data can support and record any limitations.

Timing, your team’s time and cost. Before work starts, the written proposal confirms scope, deliverables, estimated elapsed time, client time for preparation, conversations and review, and the fee and any agreed expenses. Record availability, access and the review process affect that estimate. Additional work requires an agreed change in scope.

Where and how. Based in Fort Smith, Arkansas, CE serves U.S. operations. During scoping, we agree whether on-site observation, remote review or a combination fits the work. Location, access, availability and any travel arrangements are confirmed before a commitment.

The published fixed price applies to the listed scope. Before work begins, a written proposal confirms the deliverables, responsibilities, schedule and total. Broader work receives a custom quote.