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Enter the month’s counts (orders, lines, costs, hours) and each metric’s target. The page calculates OTIF, perfect order, fill rate, lead time, damage, logistics cost and productivity, colors each one green, amber or red and tells you where to start when something is bad.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
Each card shows the result, the target, the traffic light and the calculation with your numbers. For those in caution or off target, the 3 most common causes are already open.
Result ÷ target (or target ÷ result when lower is better). The 100% line is the target.
How to read: each bar is one metric, in its traffic-light color. A bar past the 100% line = target met; the shorter, the further from target. All metrics share one scale, including lower-is-better ones (cost, lead time, damage), which are inverted so that “longer” always means “better”.
Histogram of the pasted list, with mean, median, 90th percentile and target.
How to read: each bar counts how many orders took that many days. The median splits orders in half; P90 is the time within which 9 out of 10 arrive. Good: bars bunched left of the target and P90 close to it. A long tail to the right shows forgotten or problem orders the average does not reveal.
Run of the pasted history, with the target.
How to read: each point is a month, in order. The dashed line is the target: points above it met the desired OTIF. Look at the direction of the last months more than at a single point; several months in a row below target point to a problem that is not chance.
Run of the pasted history, with the target.
How to read: each point is a month. Here lower is better: points below the dashed line are within target. Cost rising together with OTIF rising may be the price of better service (expedited freight); cost rising while OTIF falls is a sign of waste.
Key: result = value for the month; target = value entered; attainment = result ÷ target (inverted when lower is better); status = traffic light. Download as .xlsx at the end of the page.
Take this page’s results to another calculator with the fields already filled in.
The calculation report gathers this page's inputs, results, equations, assumptions and references, with fields for project, engineer and revision. The full report also includes the charts and interpretations, in color. In the print dialog, choose Save as PDF.
OTIF (On Time In Full) is the share of orders delivered on time and complete at the same time. Count the orders that met both conditions and divide by total shipped: 1,068 ÷ 1,200 = 89%. Do not just multiply the two percentages if you have the joint count: the product is only an estimate.
The perfect order also requires the order to arrive undamaged and with correct documents. That is why it is always less than or equal to OTIF. In the example, OTIF is 89% and the perfect order 85%.
In industrial distribution, 95% is a common market reference; large retailers often require 97–98% by contract. There is no universal number: start from the average of recent months and raise it gradually by changing the process.
Both. The unit fill rate is almost always higher because shortages are usually partial. The line fill rate shows how many items the customer did not get and relates more closely to complaints.
Because customers feel every order. A 3-day average can hide 10% of orders taking more than 5 days. P90 is the lead time you can keep 9 times out of 10: the honest number to promise.
It varies a lot with product and region: heavy, cheap products have a high percentage; light, expensive ones a low one. Use your own history as the reference and also track cost per order and per lb, which do not move with selling price.
Record the reason for each late or short order and paste the list of causes in the Pareto field. The “Pareto of delay causes” button opens the chart already filled in; usually two or three causes, such as stockouts and carrier delays, explain most of it.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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