Calculator Inputs
Example Data
Use this example to validate your inputs and expected output patterns.
| Planned Units | Actual Units | Scheduled (min) | Non-Work (min) | Downtime (min) | Defects (%) | Rework (min) | Value-Added (min) | Lead Time (min) | On-time (%) | Score | Rating |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 200 | 185 | 480 | 60 | 25 | 3 | 15 | 300 | 700 | 90 | 85.15 | Strong |
Tip: If your score is low, inspect the component cards above for the biggest drop.
Formula Used
The calculator builds five normalized components (each from 0 to 1) and combines them using your weights.
Availability Factor = (Effective Scheduled − Downtime) ÷ Effective Scheduled
Quality Factor = (1 − Defect Rate) × (1 − min(0.40, Rework ÷ Uptime))
Flow Factor = Value-Added Time ÷ Total Lead Time
On-time Factor = On-time Rate ÷ 100
Score = 100 × (Σ(weightᵢ × factorᵢ) ÷ Σ(weightᵢ))
- Effective Scheduled = Scheduled Time − Planned Non-Work Time.
- Uptime = Effective Scheduled − Downtime.
- Rework penalty caps at 40% to avoid over-punishing.
- Set a component’s weight to 0 to exclude it.
How to Use This Calculator
- Choose a reporting window (shift, day, sprint, or week).
- Enter planned and actual units for the same window.
- Fill time fields in minutes, including non-work blocks.
- Enter quality, flow, and on-time rates if you track them.
- Adjust weights to match what “good” means for you.
- Click Calculate Score to see the breakdown.
- Download CSV or PDF to share and compare runs.
Data capture that matches real work
This score uses planned units, actual units, and minutes to translate daily activity into a comparable index. Track scheduled time, then subtract planned non‑work blocks such as meetings. Record unplanned downtime separately, because it signals friction you can remove. Use consistent units across teams to avoid distorted comparisons. For services, units can be tickets closed or requests resolved. For manufacturing, units may be batches, parts, or completed daily work orders.
Balanced components and configurable weights
Five factors are normalized to 0–1 and then weighted. Throughput is capped at plan, so overproduction does not hide quality or flow issues. Availability focuses on uptime within effective scheduled minutes. Quality starts from defect rate and is reduced further when rework consumes uptime, with the penalty capped at 40%. Flow efficiency is value‑added minutes divided by total lead time. On‑time rate reflects commitment reliability. Set weights to mirror business cost, not personal preference.
Interpreting results with actionable thresholds
A score above 90 typically indicates stable delivery with limited waste. Scores from 75–89 often show one dominant constraint; check the lowest factor card first. At 60–74, you usually have two competing issues, such as downtime plus rework. Below 60, reduce variation: tighten definitions, improve data capture, and run shorter review cycles. Compare week over week instead of day over day. Aim for three consecutive rises before changing weights.
Operational metrics to pair with the score
Use net throughput per hour to validate that improvements are real, not just longer shifts. Monitor effective scheduled minutes and downtime minutes as separate lines in your report. Add a simple WIP snapshot to explain lead time changes; rising WIP with flat throughput usually predicts delays. When quality improves, rework minutes should fall before defect rate does. If flow drops, inspect queues, handoffs, and approval latency.
Reporting cadence and exportable evidence
Run the calculator at the end of each shift, sprint, or service window. Export CSV for trend charts and PDF for stakeholder updates, audits, and retrospectives. Keep the same weights for one month, then adjust them deliberately to reinforce the behavior you want. Store exports with dates so you can explain why the score moved. Keep notes on incidents for cleaner comparisons later. Use the PDF for reviews and the CSV for dashboards and alerts.
FAQs
What does the score represent?
It is a 0–100 index combining throughput, availability, quality, flow efficiency, and on‑time delivery. Each component is normalized, weighted, and averaged, giving a single number you can trend across time windows.
Why is throughput capped at the plan?
Capping prevents overproduction from masking problems. If you exceed target units, the throughput factor stays at 1.0, so downtime, defects, and long lead times still reduce the final score.
How should I set the weights?
Start with the defaults for one month. Then increase weight on the component that drives your costs or commitments most, such as quality for customer impact or on‑time for service reliability.
What if I cannot measure lead time yet?
Enter lead time as the best available estimate and refine later. If you prefer, set the flow weight to 0 temporarily. Keep value‑added and lead time definitions consistent to make trends meaningful.
How does rework time change results?
Rework reduces the adjusted quality factor when it consumes uptime. The penalty is limited to 40%, so one unusual day does not dominate. If rework rises, investigate root causes before changing weights.
Can I use this for support or operations?
Yes. Define units as resolved tickets, completed requests, or handled cases. Use the same window for planned and actual units, and capture downtime like tool outages or waiting on approvals for accurate availability.