Floor Command
The plant's operating picture, read in under ten seconds.
Constraint
Top client Aarav Pharmaceuticals at day 35 (contract cadence 28 days)
- WIP queued
- 420kg
- Oldest lot age
- 9.5h
- Bottleneck attainment
- 70%
Revenue run-rate at 95.8%, cash conversion cycle at 77.8 days (target 46.2 days)
Aarav past 28-day cadence
+31.6 days above 46.2d benchmark
Working capital at 77.8 days (+31.6 drag). Top account reorder at day 35.
Details
Details
Details
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
| 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.
Ranked floor blockers and recommended interventions
₹45.0 L revenue at risk
420 kg in queue, oldest 9.5 h
10.5 h and 10.2 h accrued against 12 h limit
+25 min avg overage across 28 changeovers
₹12.0 L locked in quarantine
7-stage synchronization, buffer levels, and inter-stage queue ages
Raw Intake & Sampling
Dispensing & Kitting
Compression & Granulation
Blister & Strip Packaging
Cartoning & Shipper Pack
Quality Release & Quarantine
Finished Goods Dispatch
Trend of 6 points, from 80 to 420 kg, ending at 420 kg (Current).
Compression at 96% vs blister at 70%. Stage 3–4 queue holds 420 kg (14 drums), oldest 9.5 h.
Shift output compared against rated shift plans across lines
Palghar Unit I
Palghar Unit I
Palghar Unit I
Palghar Unit II
Palghar Unit II
Palghar Unit III
Palghar Unit III
Palghar Unit III
Palghar Tablet Unit
Palghar Unit I
Palghar Unit I
Palghar Tablet Unit
Labor productivity index and active cohort headcounts
Solid Dose Operators
24 active operators
Blister Packaging Crew
18 active operators
Liquid & Sterile Ops
16 active operators
Quality Analysts
12 active operators
Maintenance Crew
10 active operators
Blister Packaging Crew productivity index at 88% (-12 pts vs 100% baseline).
Average 55 min vs 30 min target (+25 min)
Comparing 4 values, highest 55 min.
Foil changeovers average 55 min vs 30 min target (+25 min drag). Worst pair: Aarav to Bharat (Foil) on Shift C.
Shift hygiene check-ins, overtime boundaries, and training certifications