NVAH (Non Value Added Hours) are hours that do not add value in manufacturing. Tracking and analysing them helps reduce waste and improve flow stability.

What is shopfloor management?

Shopfloor management is running daily operations using up-to-date production data: work status, staffing, quality, blockers and priorities—so teams can decide fast at the point of work.

Do we need to replace ERP/SAP to start?

No. We typically integrate with existing sources (Excel, reports, exports from ERP/SAP) and build a decision layer without a system revolution.

KoDa Systems

Efficient production management

We build an operational layer on top of your data (SAP/ERP exports, reports, Excel): TV boards for the shopfloor, loss analytics (NVAH), RFT/FPY and 5S. No IT “revolution” — with a strong focus on definitions, data quality and fast decision-making.

Book 20 minutes (no commitment) See the offer How we implement

production boards Level 1/2/3 NVAH RFT / FPY 5S audits plan vs actual

Scope

What exactly we deliver

We don’t sell “pretty screens”. We deliver a daily control system: definitions → data → visualisation → meeting rhythm → action closure.

TV boards / Level 1

Plan vs actual, statuses, priorities, material shortages, blockers, resources.

shift leader view
buffers and sequencing
clear “what blocks us”

NVAH – loss time

Clear loss codes + Pareto, trends, repeatability of causes.

standardised codes + descriptions
weekly Pareto
Top 3 losses / area

Quality (RFT/FPY)

RFT/FPY, rework, deviations — consistent rules and alert thresholds.

clear pass/fail definitions
rework reasons
trend & escalation

5S – audits & actions

A simple flow: audit → result → actions → closure, without paperwork.

area checklists
actions with due dates
management summary

Data integrations

We connect what you already have: SAP/ERP exports, reports, Excel. We reduce manual work.

field mapping
data quality validation
automated refresh

Operating rhythm

We define who looks at what, when, and what decision should follow.

Level 1/2/3
escalation rules
action closure

Implementation

How we implement — without fuzzy promises

In short: definitions first, then data, then boards — and only then automation.

4 steps

KPI & definition alignment
What we count, which source, when “start/end”, how rework is counted.
Data connection + validation
Mapping, consistency tests, data quality rules.
Pilot (2–4 weeks)
One line/area. Board + NVAH + baseline quality.
Scaling & stabilisation
More areas, 5S, reporting, automated refresh.

Outcome after the pilot

Area	What changes
Visibility	One board of truth: statuses, shortages, priorities.
Losses	Cause Pareto + action owners.
Quality	RFT/FPY counted consistently, without manual spreadsheet bookkeeping.
Decisions	Level 1/2 rhythm: faster reaction, less chaos.

Honestly: KPIs won’t improve just because a board exists. They improve when the board drives decisions and action closure.

FAQ

Questions we actually hear on the shopfloor

No marketing talk. Short answers you can quote in a meeting.

Do we need to replace SAP/ERP?

No. We typically start from exports/reports and build the operational layer (boards + analytics) without rebuilding IT.

What is NVAH and why count it?

NVAH is time that doesn’t add value: waiting, shortages, downtime, rework. Counting gives Pareto — and Pareto gives priorities.

How to avoid “other” in loss reporting?

We define a loss-code dictionary and minimum description rules. Without that, analysis becomes guessing.

How long is the pilot?

Usually 2–4 weeks: quick implementation in one area, then scaling decision.

Contact

Want to see it on your data?

Tell us what you want to improve (shortages, downtime, quality, delivery). We’ll respond with a pilot proposal.

Go to the form kontakt@koda-systems.com Knowledge base