Floor Command

The plant's operating picture, read in under ten seconds.

Executive

Shift B in progress — 32 min of 480 elapsed (6.7%)

Facility:

All Palghar Unit I Palghar Unit II Palghar Unit III Palghar Tablet Unit Greenfield Plant

Shift:

Current Previous Last 7d Last 30d

Compare:

vs Plan vs Same Weekday

Role:

Executive Plant Head Line Supervisor Finance

Constraint

Top client Aarav Pharmaceuticals at day 35 (contract cadence 28 days)

WIP queued: 420kg
Oldest lot age: 9.5h
Bottleneck attainment: 70%

Why? Review reallocation

Plan AttainmentLiveDerived

100.0%

5 vs planTarget 95%ok

Line UtilizationLiveDerived

87.0%

2 vs targetTarget 85%ok

WIP (bulk to pack)LiveReported

95kg

105 vs limitLimit 200 kgok

Details

95 kg in 4 drums. Oldest item: 2.5 hours in queue.

Avg ChangeoverLiveReported

55min

25 vs targetTarget 30 mincritical

Details

Worst pair: Aarav to Bharat (Foil)

Labor ProductivityLiveDerived

102.4%

2.4 vs targetTarget 100%ok

Release TurnaroundLiveReported

31.2h

7.2 vs targetTarget 24 hcritical

Details

Quarantine value: ₹12.0 L

Commercial Pulse & Working Capital(Inspect commercial accounts)

Revenue run-rate at 95.8%, cash conversion cycle at 77.8 days (target 46.2 days)

Monthly Revenue Run-Rate

95.8%of budget

Top 10 Client Share

49%concentration

Reorder Radar Exposure

₹45.0 L(1 account)

Aarav past 28-day cadence

Cash Conversion Cycle

77.8dayscritical

+31.6 days above 46.2d benchmark

Working capital at 77.8 days (+31.6 drag). Top account reorder at day 35.

Attention & Next Actions(View all approvals)

Ranked floor blockers and recommended interventions

Top client Aarav Pharmaceuticals at day 35 (contract cadence 28 days)

₹45.0 L revenue at risk

critical

Owner: executiveReview action

Stage 3 to 4 bottleneck: 420 kg WIP queued at Blister Line 1

420 kg in queue, oldest 9.5 h

critical

Owner: plant-headReview action

2 key operators within 2 h of weekly overtime ceiling

10.5 h and 10.2 h accrued against 12 h limit

watch

Owner: line-supervisorReview action

Foil format changeovers +25 min over target (Shift C worst)

+25 min avg overage across 28 changeovers

watch

Owner: line-supervisorReview action

Microbiology lab turnaround 31.2 h vs 24 h target (Monday delay)

₹12.0 L locked in quarantine

watch

Owner: plant-headReview action

Stage Flow & WIP Queues(Inspect Line Balances)

7-stage synchronization, buffer levels, and inter-stage queue ages

Stage 1INTAKE

Raw Intake & Sampling

98%/ 100%

65 kg2 drums1.4h

Stage 2DISPENSE

Dispensing & Kitting

95%/ 100%

80 kg3 drums2.1h

Stage 3BULK

Compression & Granulation

96%/ 100%

420 kg14 drums9.5h

Stage 4PACK-1

Blister & Strip Packaging

70%/ 100%

75 kg3 drums1.8h

Stage 5PACK-2

Cartoning & Shipper Pack

92%/ 100%

50 kg2 drums1.1h

Stage 6QC-REL

Quality Release & Quarantine

88%/ 100%

35 kg1 drums0.9h

Stage 7DISPATCH

Finished Goods Dispatch

94%/ 100%

Stage 3 to 4 buffer growth (last 6 shifts)Threshold: 200 kg

Compression at 96% vs blister at 70%. Stage 3–4 queue holds 420 kg (14 drums), oldest 9.5 h.

QC Release & Quarantine(Inspect quality samples)

Turnaround 31.2 h vs 24 h target (₹12.0 L held in quarantine)

Lab Release Turnaround

31.2 hours avg

Quarantine Impact

₹12.0 L

critical

Category	Mon	Tue	Wed	Thu	Fri	Sat	Sun
Microbiology	34.0h	22.5h	22.5h	22.5h	22.5h	22.5h	22.5h
Analytical Chem	18.0h	18.0h	18.0h	18.0h	18.0h	18.0h	18.0h
Packaging QC	12.0h	12.0h	12.0h	12.0h	12.0h	12.0h	12.0h

Microbiology turnaround averages 31.2 h vs 24 h target, with Monday cohorts delaying batch release and ₹12.0 L held in quarantine.

Line Performance & Attainment(Inspect All Lines)

Shift output compared against rated shift plans across lines

Liquid Oral Line A

Palghar Unit III

94%(-6%)watch

Liquid Line B

Palghar Unit III

94%(-6%)watch

Bottling Line 1

Palghar Unit III

94%(-6%)watch

Changeovers(View detail)

Avg 55 min vs 30 min target

Worst pair: Aarav to Bharat (Foil) (61 min)Details

Workforce & Productivity(Inspect workforce details)

Labor productivity index and active cohort headcounts

Solid Dose Operators

24 active operators

104%ok

Blister Packaging Crew

18 active operators

88%watch

Liquid & Sterile Ops

16 active operators

98%ok

Quality Analysts

12 active operators

92%watch

Maintenance Crew

10 active operators

100%ok

Blister Packaging Crew productivity index at 88% (-12 pts vs 100% baseline).

Compliance & Regulatory Health(Inspect compliance log)

Shift hygiene check-ins, overtime boundaries, and training certifications

Weekly Overtime: 2 operators within 2 h of ceiling (Rajesh Sharma (1.5h left), Amit Patel (1.8h left))

watch

Shift Hygiene Check-In: 98.5%

SOP Training Currency: 96%