Rapid Measurement of Labor Efficiency with Automated Excel Dashboards in High-Mix Manufacturing Lines

Authors: Sai Prasad Ravulapally

DOI: https://doi.org/10.37082/IJIRMPS.v14.i1.233026

Short DOI: https://doi.org/hbtwcd

Country: United States

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Abstract: Companies that make a lot of different things in a short amount of time often have trouble assessing labor efficiency across production lines in a precise and consistent way. Calculations done by supervisors are usually done by hand, take a long time, and are not always accurate. This makes it hard for leaders to see what is going on and slows down decision-making. This paper presents a case study showing the design, implementation, and impact of an automated Excel-based dashboard designed to rapidly monitor Direct Labor (DL) efficiency in an outdoor power equipment manufacturing facility that manufactures outdoor power equipment. The deployed system coordinated labor efficiency projections across five assembly lines and cut the time it took to report from 20 to 30 minutes per line to about 2 to 3 minutes for the whole facility. The results show that reporting is more consistent, accurate, and visible to leaders, which shows how useful low-cost digital solutions can be for improving operational excellence through data.

Keywords: Manufacturing Performance Measurement, Operational Excellence, Digital Transformation in Manufacturing, Digital performance dashboards, Lean Manufacturing, Labor efficiency and performance, Automated Excel dashboard, operational excellence, Enterprise Resource Planning (ERP) and Advanced Manufacturing Execution Systems (MES).

Paper Id: 233026

Published On: 2026-02-12

Published In: Volume 14, Issue 1, January-February 2026

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