Each row is one worker across the real clock of the operation. Bar colour identifies the employee; texture identifies the activity — solid is working at a station, hatched is walking, faded is away.
Read the cv_percent column first. It is the spread as a percentage of the
average, so it flags the inconsistent steps — which is usually where
recoverable time is hiding, more so than the merely slow ones.
normal_s = mean × rating factor 1.0.
standard_s = normal + 15% allowances.
| step | observations | mean_s | median_s | min_s | max_s | std_s | cv_percent | total_s | normal_s | standard_s |
|---|---|---|---|---|---|---|---|---|---|---|
| Weld ledger blade | 14 | 47.7 | 48.0 | 38.0 | 56.0 | 4.8 | 10.0 | 667.5 | 47.7 | 54.8 |
| Cut to length | 14 | 34.0 | 34.8 | 27.5 | 40.0 | 3.8 | 11.0 | 476.0 | 34.0 | 39.1 |
| Press cup | 14 | 21.9 | 21.5 | 18.5 | 28.0 | 2.7 | 12.0 | 306.5 | 21.9 | 25.2 |
| Stack finished | 14 | 12.4 | 12.2 | 3.5 | 17.5 | 3.3 | 27.0 | 173.0 | 12.4 | 14.2 |
| Load tube | 14 | 11.0 | 10.8 | 9.0 | 13.0 | 1.1 | 10.0 | 153.5 | 11.0 | 12.6 |
Utilisation is time at a work station as a share of time on camera — not of the whole recording, so a worker who appears late is not penalised for it.
| worker | on_camera_s | work_s | walking_s | off_station_s | absent_s | utilisation_percent | walking_percent | stop_count | stop_s | stop_percent |
|---|---|---|---|---|---|---|---|---|---|---|
| Ahmed | 720.0 | 600.0 | 120.0 | 0.0 | 0.0 | 83.3 | 16.7 | 0 | 0.0 | 0.0 |
| Mahmoud | 720.0 | 615.0 | 105.0 | 0.0 | 0.0 | 85.4 | 14.6 | 1 | 17.0 | 2.8 |
| Youssef | 676.0 | 562.0 | 114.0 | 0.0 | 44.0 | 83.1 | 16.9 | 1 | 12.0 | 2.1 |
| worker | cycles | mean_cycle_s | median_cycle_s | min_cycle_s | max_cycle_s | std_cycle_s |
|---|---|---|---|---|---|---|
| Ahmed | 4 | 146.5 | 149.5 | 135.5 | 151.5 | 6.4 |
| Mahmoud | 4 | 167.1 | 167.0 | 161.0 | 173.5 | 5.2 |
| Youssef | 3 | 148.8 | 149.0 | 148.5 | 149.0 | 0.2 |
One chart per operator, showing a single repeatable cycle broken into its elements and averaged across every cycle observed. ━━ Manual is the operator's hands on the work. - - Auto / wait is the operator present at the station but not moving. ∿∿ Walk is transport, charged to the element it follows. The heavy red line is takt — demand rate. Anything to the right of it is a cycle that cannot keep up.
| worker | elements | manual_s | auto_wait_s | walk_s | cycle_s | vs_takt |
|---|---|---|---|---|---|---|
| Ahmed | 5 | 121.5 | 0.0 | 25.0 | 146.5 | +4s (within takt) |
| Mahmoud | 5 | 137.9 | 4.2 | 25.0 | 167.1 | -17s (OVER TAKT) |
| Youssef | 5 | 119.8 | 4.0 | 25.0 | 148.8 | +1s (within takt) |
| worker | seq | element | manual_s | auto_s | walk_s | start_s | element_total_s | cumulative_s | observations |
|---|---|---|---|---|---|---|---|---|---|
| Ahmed | 1 | Load tube | 11.0 | 0.0 | 5.0 | 0.0 | 16.0 | 16.0 | 4 |
| Ahmed | 2 | Cut to length | 33.5 | 0.0 | 5.0 | 16.0 | 38.5 | 54.5 | 4 |
| Ahmed | 3 | Press cup | 22.4 | 0.0 | 5.0 | 54.5 | 27.4 | 81.9 | 4 |
| Ahmed | 4 | Weld ledger blade | 42.5 | 0.0 | 5.0 | 81.9 | 47.5 | 129.4 | 4 |
| Ahmed | 5 | Stack finished | 12.1 | 0.0 | 5.0 | 129.4 | 17.1 | 146.5 | 4 |
| Mahmoud | 1 | Load tube | 12.0 | 0.0 | 5.0 | 0.0 | 17.0 | 17.0 | 4 |
| Mahmoud | 2 | Cut to length | 36.4 | 0.0 | 5.0 | 17.0 | 41.4 | 58.4 | 4 |
| Mahmoud | 3 | Press cup | 24.1 | 0.0 | 5.0 | 58.4 | 29.1 | 87.5 | 4 |
| Mahmoud | 4 | Weld ledger blade | 49.4 | 4.2 | 5.0 | 87.5 | 58.6 | 146.1 | 4 |
| Mahmoud | 5 | Stack finished | 16.0 | 0.0 | 5.0 | 146.1 | 21.0 | 167.1 | 4 |
| Youssef | 1 | Load tube | 10.5 | 0.0 | 5.0 | 0.0 | 15.5 | 15.5 | 3 |
| Youssef | 2 | Cut to length | 29.3 | 4.0 | 5.0 | 15.5 | 38.3 | 53.8 | 3 |
| Youssef | 3 | Press cup | 21.3 | 0.0 | 5.0 | 53.8 | 26.3 | 80.2 | 3 |
| Youssef | 4 | Weld ledger blade | 47.3 | 0.0 | 5.0 | 80.2 | 52.3 | 132.5 | 3 |
| Youssef | 5 | Stack finished | 11.3 | 0.0 | 5.0 | 132.5 | 16.3 | 148.8 | 3 |
Work content per operator, per cycle. Uneven columns mean the line is unbalanced: the tallest column sets the pace and every shorter one is waiting.
Every worker's floor path over the whole recording. Dense tangles are walking that the layout is forcing.
Every stop and departure, in order.
| worker | event | at | duration_s | step |
|---|---|---|---|---|
| Mahmoud | STOPPED | 4:24 | 17.0 | Weld ledger blade |
| Youssef | STOPPED | 5:26 | 12.0 | Cut to length |
| Youssef | LEFT | 9:46 | 44.0 | NaN |
Every step each worker performed, in order, with its start time and duration —
the same content as steps.txt in this run folder. This is the listing to
check against what you saw on the floor.
================================================================================================
LABOUR STEP BREAKDOWN - DEMO - synthetic data
Camera cuplock_line_cam1 | recording 12:00 | analysed at 2.0 fps
================================================================================================
------------------------------------------------------------------------------------------------
AHMED | 83% utilisation | 0 stop(s) | 4 cycles, mean 146.5s
------------------------------------------------------------------------------------------------
# Start Step Duration Notes
--- ------- -------------------------------------------- ----------------------
--- CYCLE 1 (starts 0:00, lasts 148.5s) ---
1 0:00 Load tube 11.5 s
2> 0:12 walking / transport 5.0 s
3 0:16 Cut to length 35.0 s
4> 0:52 walking / transport 5.0 s
5 0:56 Press cup 21.0 s
6> 1:18 walking / transport 5.0 s
7 1:22 Weld ledger blade 43.5 s
8> 2:06 walking / transport 5.0 s
9 2:11 Stack finished 12.5 s
10> 2:24 walking / transport 5.0 s
--- CYCLE 2 (starts 2:28, lasts 151.5s) ---
11 2:28 Load tube 9.5 s
12> 2:38 walking / transport 5.0 s
13 2:43 Cut to length 34.5 s
14> 3:18 walking / transport 5.0 s
15 3:22 Press cup 25.0 s
16> 3:48 walking / transport 5.0 s
17 3:52 Weld ledger blade 45.5 s
18> 4:38 walking / transport 5.0 s
19 4:43 Stack finished 12.0 s
20> 4:55 walking / transport 5.0 s
--- CYCLE 3 (starts 5:00, lasts 150.5s) ---
21 5:00 Load tube 11.5 s
22> 5:12 walking / transport 5.0 s
23 5:16 Cut to length 35.5 s
24> 5:52 walking / transport 5.0 s
25 5:57 Press cup 22.5 s
26> 6:20 walking / transport 5.0 s
27 6:24 Weld ledger blade 43.0 s
28> 7:08 walking / transport 5.0 s
29 7:12 Stack finished 13.0 s
30> 7:26 walking / transport 5.0 s
--- CYCLE 4 (starts 7:30, lasts 135.5s) ---
31 7:30 Load tube 11.5 s
32> 7:42 walking / transport 5.0 s
33 7:47 Cut to length 29.0 s
34> 8:16 walking / transport 5.0 s
35 8:21 Press cup 21.0 s
36> 8:42 walking / transport 5.0 s
37 8:47 Weld ledger blade 38.0 s
38> 9:25 walking / transport 5.0 s
39 9:30 Stack finished 11.0 s
40> 9:41 walking / transport 5.0 s
41 9:46 Load tube 9.0 s
42> 9:55 walking / transport 5.0 s
43 10:00 Cut to length 33.0 s
44> 10:33 walking / transport 5.0 s
45 10:38 Press cup 19.0 s
46> 10:57 walking / transport 5.0 s
47 11:02 Weld ledger blade 49.5 s
48> 11:52 walking / transport 5.0 s
49 11:56 Stack finished 3.5 s
ELEMENT SUMMARY - Ahmed
Step Obs Mean Min Max SD Consistency
Weld ledger blade 5 43.9s 38.0s 49.5s 3.7s consistent (9%)
Cut to length 5 33.4s 29.0s 35.5s 2.4s consistent (7%)
Press cup 5 21.7s 19.0s 25.0s 2.0s consistent (9%)
Load tube 5 10.6s 9.0s 11.5s 1.1s variable (11%)
Stack finished 5 10.4s 3.5s 13.0s 3.5s UNSTABLE (34%)
------------------------------------------------------------------------------------------------
MAHMOUD | 85% utilisation | 1 stop(s) | 4 cycles, mean 167.1s
------------------------------------------------------------------------------------------------
# Start Step Duration Notes
--- ------- -------------------------------------------- ----------------------
--- CYCLE 1 (starts 0:00, lasts 161.0s) ---
1 0:00 Load tube 12.5 s
2> 0:12 walking / transport 5.0 s
3 0:18 Cut to length 29.0 s
4> 0:46 walking / transport 5.0 s
5 0:52 Press cup 24.0 s
6> 1:16 walking / transport 5.0 s
7 1:20 Weld ledger blade 55.0 s
8> 2:16 walking / transport 5.0 s
9 2:20 Stack finished 15.5 s
10> 2:36 walking / transport 5.0 s
--- CYCLE 2 (starts 2:41, lasts 163.0s) ---
11 2:41 Load tube 10.5 s
12> 2:52 walking / transport 5.0 s
13 2:56 Cut to length 37.5 s
14> 3:34 walking / transport 5.0 s
15 3:39 Press cup 22.5 s
16> 4:02 walking / transport 5.0 s
17 4:06 Weld ledger blade 51.0 s includes 17s STOPPED
18> 4:58 walking / transport 5.0 s
19 5:02 Stack finished 16.5 s
20> 5:19 walking / transport 5.0 s
--- CYCLE 3 (starts 5:24, lasts 171.0s) ---
21 5:24 Load tube 12.0 s
22> 5:36 walking / transport 5.0 s
23 5:41 Cut to length 39.0 s
24> 6:20 walking / transport 5.0 s
25 6:25 Press cup 28.0 s
26> 6:53 walking / transport 5.0 s
27 6:58 Weld ledger blade 52.5 s
28> 7:50 walking / transport 5.0 s
29 7:56 Stack finished 14.5 s
30> 8:10 walking / transport 5.0 s
--- CYCLE 4 (starts 8:15, lasts 173.5s) ---
31 8:15 Load tube 13.0 s
32> 8:28 walking / transport 5.0 s
33 8:33 Cut to length 40.0 s
34> 9:13 walking / transport 5.0 s
35 9:18 Press cup 22.0 s
36> 9:40 walking / transport 5.0 s
37 9:45 Weld ledger blade 56.0 s
38> 10:41 walking / transport 5.0 s
39 10:46 Stack finished 17.5 s
40> 11:04 walking / transport 5.0 s
41 11:08 Load tube 10.5 s
42> 11:19 walking / transport 5.0 s
43 11:24 Cut to length 36.0 s
ELEMENT SUMMARY - Mahmoud
Step Obs Mean Min Max SD Consistency
Weld ledger blade 4 53.6s 51.0s 56.0s 2.0s consistent (4%)
Cut to length 5 36.3s 29.0s 40.0s 3.9s variable (11%)
Press cup 4 24.1s 22.0s 28.0s 2.4s consistent (10%)
Stack finished 4 16.0s 14.5s 17.5s 1.1s consistent (7%)
Load tube 5 11.7s 10.5s 13.0s 1.0s consistent (9%)
------------------------------------------------------------------------------------------------
YOUSSEF | 83% utilisation | 1 stop(s) | 3 cycles, mean 148.8s
------------------------------------------------------------------------------------------------
# Start Step Duration Notes
--- ------- -------------------------------------------- ----------------------
--- CYCLE 1 (starts 0:00, lasts 149.0s) ---
1 0:00 Load tube 10.5 s
2> 0:10 walking / transport 5.0 s
3 0:16 Cut to length 29.5 s
4> 0:45 walking / transport 5.0 s
5 0:50 Press cup 25.0 s
6> 1:15 walking / transport 5.0 s
7 1:20 Weld ledger blade 48.5 s
8> 2:08 walking / transport 5.0 s
9 2:14 Stack finished 10.5 s
10> 2:24 walking / transport 5.0 s
--- CYCLE 2 (starts 2:29, lasts 149.0s) ---
11 2:29 Load tube 10.0 s
12> 2:39 walking / transport 5.0 s
13 2:44 Cut to length 34.0 s
14> 3:18 walking / transport 5.0 s
15 3:23 Press cup 20.0 s
16> 3:43 walking / transport 5.0 s
17 3:48 Weld ledger blade 48.0 s
18> 4:36 walking / transport 5.0 s
19 4:41 Stack finished 12.0 s
20> 4:53 walking / transport 5.0 s
--- CYCLE 3 (starts 4:58, lasts 148.5s) ---
21 4:58 Load tube 11.0 s
22> 5:09 walking / transport 5.0 s
23 5:14 Cut to length 36.5 s includes 12s STOPPED
24> 5:50 walking / transport 5.0 s
25 5:56 Press cup 19.0 s
26> 6:14 walking / transport 5.0 s
27 6:20 Weld ledger blade 45.5 s
28> 7:05 walking / transport 5.0 s
29 7:10 Stack finished 11.5 s
30> 7:22 walking / transport 5.0 s
31 7:26 Load tube 10.5 s
32> 7:37 walking / transport 5.0 s
33 7:42 Cut to length 27.5 s
34> 8:10 walking / transport 5.0 s
35 8:14 Press cup 19.0 s
36> 8:34 walking / transport 5.0 s
37 8:38 Weld ledger blade 43.5 s
38> 9:22 walking / transport 5.0 s
39 9:27 Stack finished 13.5 s
40> 9:40 walking / transport 6.0 s
41X 9:46 LEFT - out of view 44.0 s departure
42> 10:30 walking / transport 3.5 s
43 10:34 Press cup 18.5 s
44> 10:52 walking / transport 5.0 s
45 10:58 Weld ledger blade 48.0 s
46> 11:46 walking / transport 5.0 s
47 11:50 Stack finished 9.5 s
ELEMENT SUMMARY - Youssef
Step Obs Mean Min Max SD Consistency
Weld ledger blade 5 46.7s 43.5s 48.5s 1.9s consistent (4%)
Cut to length 4 31.9s 27.5s 36.5s 3.6s variable (11%)
Press cup 5 20.3s 18.5s 25.0s 2.4s variable (12%)
Stack finished 5 11.4s 9.5s 13.5s 1.4s variable (12%)
Load tube 4 10.5s 10.0s 11.0s 0.4s consistent (3%)
================================================================================================
ALL WORKERS - WORK ELEMENT TIMES
================================================================================================
Step Obs Mean Median SD Normal Std Consistency
Weld ledger blade 14 47.7s 48.0s 4.8s 47.7s 54.8s variable (10%)
Cut to length 14 34.0s 34.8s 3.8s 34.0s 39.1s variable (11%)
Press cup 14 21.9s 21.5s 2.7s 21.9s 25.2s variable (12%)
Stack finished 14 12.4s 12.2s 3.3s 12.4s 14.2s UNSTABLE (27%)
Load tube 14 11.0s 10.8s 1.1s 11.0s 12.6s consistent (10%)
Normal = mean x rating factor 1.0
Standard = normal x (1 + 15% allowances)
The rating factor is a HUMAN judgement. This system does not estimate
worker pace - no standard time above is valid without a qualified observer.
================================================================================================
STOPS AND DEPARTURES
================================================================================================
At Worker Event Detail
4:24 Mahmoud STOPPED 17.0s during Weld ledger blade
5:26 Youssef STOPPED 12.0s during Cut to length
9:46 Youssef LEFT 44.0s out of view
================================================================================================
STANDARD WORK COMBINATION TABLE
================================================================================================
Manual = operator's hands are on the work
Auto/wait = operator present at the station but not moving. Video cannot
separate machine cycle time from avoidable waiting - that split
is a judgement for whoever knows the equipment cycle times.
Walk = transport between stations, attributed to the element it follows
AHMED
# Element Manual Auto/wait Walk Total Cum.
1 Load tube 11.0s 0.0s 5.0s 16.0s 16.0s
2 Cut to length 33.5s 0.0s 5.0s 38.5s 54.5s
3 Press cup 22.4s 0.0s 5.0s 27.4s 81.9s
4 Weld ledger blade 42.5s 0.0s 5.0s 47.5s 129.4s
5 Stack finished 12.1s 0.0s 5.0s 17.1s 146.5s
TOTAL 121.5s 0.0s 25.0s 146.5s
Takt 150s -> +3.5s (within takt)
MAHMOUD
# Element Manual Auto/wait Walk Total Cum.
1 Load tube 12.0s 0.0s 5.0s 17.0s 17.0s
2 Cut to length 36.4s 0.0s 5.0s 41.4s 58.4s
3 Press cup 24.1s 0.0s 5.0s 29.1s 87.5s
4 Weld ledger blade 49.4s 4.2s 5.0s 58.6s 146.1s
5 Stack finished 16.0s 0.0s 5.0s 21.0s 167.1s
TOTAL 137.9s 4.2s 25.0s 167.1s
Takt 150s -> -17.1s (OVER TAKT - cannot meet demand)
YOUSSEF
# Element Manual Auto/wait Walk Total Cum.
1 Load tube 10.5s 0.0s 5.0s 15.5s 15.5s
2 Cut to length 29.3s 4.0s 5.0s 38.3s 53.8s
3 Press cup 21.3s 0.0s 5.0s 26.3s 80.2s
4 Weld ledger blade 47.3s 0.0s 5.0s 52.3s 132.5s
5 Stack finished 11.3s 0.0s 5.0s 16.3s 148.8s
TOTAL 119.8s 4.0s 25.0s 148.8s
Takt 150s -> +1.2s (within takt)