Live Derived KPIs — updates with filters ↓
Data-Backed Findings & Action Items
Spain improved +32% and Singapore +253% over the same period. USA is the only plant moving backwards. Root causes to investigate: equipment age vs Spain/Singapore, operator turnover post-2022, and product mix complexity (Pours/Batch rose +6.9% = harder runs). Automation rate is flat at ~45% while Spain jumped 10% → 50%.
⚡ Quick fix — Benchmark Spain's 2023 automation programme: what was automated, at what cost, in how long?
USA receives the same raw material volume in 69% more, smaller lots than 5 years ago. Each lot requires QC sign-off, administrative handling, and storage allocation. Spain reduced theirs by 18% — this is a supplier negotiation win. A 30% reduction in USA lots/ton ≈ 2–3 working days saved/month in intake handling.
⚡ Quick fix — Call top 3 USA suppliers. Negotiate minimum lot size × 2. No capital, no process change.
Singapore regularly ships multiples of its monthly production. This signals either (A) a distribution hub model (ships from stock) or (B) a data timing mismatch creating P&L distortion. USA is the most consistent (avg 0.96×, max 1.29×). Until Singapore's model is formally classified, fill rate and yield KPIs are unreliable for this site.
⚡ Quick fix — Add Cumulative Inventory Buffer = Σ Produced − Σ Shipped. A negative value is a data integrity flag.
USA makes 42% more delivery trips per customer than Singapore. At ~290 shipments/month avg, closing the gap to Spain's 1.60 ratio eliminates ~130 shipments/month — roughly 1,500 shipments/year of pure logistics cost, zero revenue impact.
⚡ Quick fix — Implement 48-hr order consolidation window in WMS for USA customers with multiple open orders.
December underperformance is structural, not situational. Spain ships 39% fewer orders in December than its annual average, every single year. This is deferred Q4 revenue pushed into Q1. Spain's October index is 109 — production capacity exists to pre-build.
⚡ Quick fix — Brief Spain & USA sales in October: pull forward December orders. Even 20% pull-forward adds ~$Xk to Q4 revenue.
Spain's automation investment delivered a clear +32% throughput lift. But growth stalled at 50% and Kilo/hr plateaued. The next lever is batch densification (Pours/Batch +5.2% trend is correct) combined with lot consolidation (already −18%). USA's Automation Yield Premium is −7.7% — meaning automation is not translating to throughput in Florida. Investigate what is being automated and whether it is the right process.
⚡ Quick fix — Copy Spain's 2023 automation playbook to USA. Request internal knowledge transfer.
Singapore's batch density has declined 21% since 2022. Fewer pours per batch = more setup overhead per unit of output. Combined with extreme production volatility (CoV 111%), this suggests either a product mix shift toward short specialised runs or batches being interrupted before completion. Cross-referencing with PctBatchesBases trend will identify whether this is strategic or operational.
⚡ Quick fix — Add control limit on Pours/Batch (target ≥85% of rolling 12m max). Flag breaches in anomaly panel.
① Throughput Index (2023 Baseline)
Kilo/hr indexed to 2023 = 100 · Spain +45% · USA flat · Singapore volatile
② Procurement Lot Fragmentation (Lots/Ton)
USA +69% since 2021 · Spain −18% · fewer lots = less QC overhead · target ≤ 7.0
③ Shipment Fragmentation Index (Shipments/Customer)
USA above 2.0 and rising · Spain/Singapore best-in-class · target ≤ 1.70
④ Cumulative Inventory Buffer (Produced − Shipped)
All-time Σ Tons produced minus Σ Tons shipped · declining or negative = drawdown alert
⑤ Material Conversion Efficiency (%)
Tons Shipped ÷ Raw Mat Received × 100 · target ≥ 90% · Singapore extremes = hub model signal
⑥ Automation Yield Premium (%)
Rolling: Kilo/hr in high-auto months vs low-auto months · Spain +34% ✅ · USA negative 🔴
⑦ Batch Efficiency Ratio (%)
Actual Pours/Batch ÷ site rolling 12m max × 100 · target ≥ 90% · Singapore trending down
⑧ Seasonal Coverage Index (%)
Nov production ÷ expected Dec gap × 100 · target ≥ 50% · plan pre-build from October