BOHO ALTA Production Handbook

BOHO ALTA · WW Lab · Master Production Handbook

WW Laboratory · Internal Operations Framework · 2025

BOHO ALTA

Crafted with Purpose. Executed with Precision.

Master Production Handbook

The complete operational reference for the ALTA Production Team — covering all production workflows, quality standards, sustainability practices, team roles, KPIs, and compliance checklists.

44 Framework Items

10 Process Categories

14 Production Stages

8 Core KPIs

"Every BOHO piece carries the soul of its artisan, the values of sustainability, and the beauty of timeless design."

Contents

Framework Index

This handbook integrates all operational, quality, culture, and compliance documentation for the BOHO ALTA WW Laboratory. Organized across 10 process categories with 44 framework items.

01Finance & Billing6 items

02Orders & Customer Management3 items

03Production Operations9 items

04Quality Control2 items

05Packaging2 items

06Delivery & Logistics6 items

07Inventory & Procurement4 items

08HR & People Management5 items

09Culture, Values & Compliance4 items

10Meetings & Reporting5 items

★Master Execution ChecklistAll stages

★KPI Compliance Tracker8 KPIs

Framework Gap Notice

11 additional items have been identified as critical operational gaps and are marked throughout this handbook as + NEW / RECOMMENDED. These include: Raw Material Tracker, Vendor Master List, Returns & Refund SOP, Failed Delivery Log, Equipment Maintenance Log, Shift Roster, Leave Management Tracker, Employee Onboarding Checklist, Non-Conformance Log, Customer Database, and Product Catalog.

Foundation

Core Team Roles & Responsibilities

Clear role ownership prevents gaps and duplication. Every stage has a designated owner with defined accountability.

◈

Executive, Creative Operations & Execution

Converts confirmed requirements into actionable production briefs. Coordinates across sales, design, workshop, packaging, and dispatch. Owns overall execution visibility and deadline tracking.

Owns: Production trigger · Dispatch readiness · Closure

◇

Production Manager / Coordinator

Plans batch flow and maker allocation. Issues work orders and daily priorities. Tracks stage completion and escalates delays.

Owns: Production planning · Work order release · Stage tracking

◻

Procurement / Inventory Executive

Checks raw material availability. Receives incoming material, verifies counts, updates stock records, and flags shortages or damage.

Owns: Material availability · Intake · Storage records

◐

Workshop Supervisor

Assigns work to artisans and makers. Monitors floor discipline, quality, pace, and material usage. Reports production risks immediately.

Owns: Making/fabrication stage · In-process QC coordination

◎

QC Executive

Conducts inspection at intake, in-process, and finished stages. Checks finish, measurements, structural integrity, and visual consistency. Approves or rejects movement.

Owns: In-process QC · Final QC · Rework tracking

◳

Packaging & Fulfillment / Delivery Coordinator

Prepares packing materials, labels, inserts, dispatch checklists. Schedules courier or in-house delivery. Ensures goods released only after final approval.

Owns: Packaging stage · Dispatch readiness · Delivery handover

Visual Reference

Production Workflow — End to End

14 stages from order confirmation to closure. Every stage has an owner, target time, and documented handoff.

Production Flow

Order Confirmed

Trigger · Brief Created

Material Availability Check

Reserve stock · Raise requisition

shortage

Procurement

Raw Material Intake

Receive · Label · Log

Material Inspection (QC)

Clay · Wax · Textiles · Jute

Production Planning

Schedule · Allocate makers · Targets

Work Order Release

Job ID · Specs · Materials issued

Making / Fabrication

Pottery · Candles · Textiles · Spa

In-Process QC (Hourly)

Shape · Seams · Texture · Defects

Finishing

Polish · Coat · Cure · Protect

Final QC

Full inspection · Sign-off required

Packaging & Labeling

Eco-pack · BOHO branding · Labels

Dispatch Readiness Check

Quantity · Address · Challan · Vehicle

Delivery / Installation

Safe load · Handover · POD signed

Closure & Record Update

Log · Variance · Learning · Close

Handoff Rules

Nothing Moves Without Record

Every stage completion must be reflected in the tracker before the next stage begins.

Incomplete Input Blocks

If dimensions, material, or quantity are unclear, production must pause for clarification.

QC Controls Movement

No intake material becomes active stock without inspection. No finished item ships without final QC pass.

Urgent Orders Still Follow Controls

Rush orders may shorten times, but cannot remove approval, QC, or documentation requirements.

Rework Must Be Visible

All rework must be logged with reason, owner, and revised completion target. No silent corrections.

Stage Time Targets

#	Stage	Target
01	Production Trigger	Same day / 1–2 hrs
02	Material Availability Check	Same day / 2–4 hrs
03	Raw Material Intake	Same day on arrival
04	Material Inspection & Storage	Same day to 24 hrs
05	Production Planning	Daily / before shift
06	Work Order Release	Same day as planning
07	Making / Fabrication	Per SKU standard
08	In-Process QC	Same shift
09	Finishing	Per SKU; curing planned
10	Final QC	12–24 hrs after finishing
11	Packaging & Labeling	Same day to 24 hrs
12	Dispatch Readiness	Same day before cut-off
13	Delivery / Installation	Per dispatch plan
14	Closure & Record Update	Within 24 hrs of delivery

Status Flow Reference

ORDER STATUS

Confirmed

›

In Planning

›

In Production

›

In Finishing

›

QC Pending

›

Ready to Pack

›

Ready to Dispatch

›

Delivered

›

Closed

QC STATUS

Pending

›

Passed

›

Rework

›

Rejected

›

Passed After Rework

Category 03 · 9 Items

Production Operations

Stage-by-stage SOPs for every production activity — from trigger to closure. Each stage defines owner, actions, checkpoints, and handoffs.

Production Trigger

Same day / 1–2 hrs Executive + Sales → Production Coordinator

Executive, Creative Operations & ExecutionSales / Order Management

01Verify order is confirmed and approved.
02Confirm product specifications are complete (SKU, quantity, dimensions, material, finish, delivery date).
03Confirm payment or internal approval status.
04Create or update production brief with all required inputs.
05Send production trigger to Production Coordinator.

No production starts without a complete brief.

Handoff to: Production Coordinator

Material Availability Check

Same day / 2–4 hrs Production Coordinator + Inventory

Production CoordinatorInventory / Procurement Executive

01Review bill of materials or practical material list from production brief.
02Check available stock of primary materials, accessories, finishing items, and packaging.
03Identify shortages, substitute options, or urgent procurement needs.
04Reserve available stock against the production order in the inventory system.

Possible Outputs: Material fully available → proceed to production planning. Partial → reserve + initiate procurement. Shortage → raise purchase request before planning.

Stock must be reserved in record before release.

Handoff to: Procurement / Inventory or Production Coordinator

Raw Material Intake

Same day on arrival Inventory / Procurement Executive

Inventory / Procurement Executive

01Receive material from vendor or internal transfer.
02Match received quantity against the purchase order or requisition document.
03Check basic physical condition upon receipt.
04Record material receipt date, vendor name, quantity, and reference number.
05Label and segregate material by category in the storage area.

Unlabeled or unrecorded material cannot enter usable stock.

Handoff to: QC Executive + Inventory Storage

Material Inspection & Storage

Same day to 24 hrs QC Executive + Inventory Executive

QC ExecutiveInventory Executive

Inspection Criteria: Defects / breakage · Color mismatch / finish inconsistency · Warping, staining, moisture impact · Incorrect dimensions or size deviation

01Inspect each batch against the criteria above.
02Separate material into three categories: Approved, Conditional, and Rejected.
03Update stock records accordingly.
04Store approved items in designated storage zones.
05Tag fragile, premium, or urgent-use material appropriately.

Rejected material must be physically isolated and vendor follow-up logged.

Handoff to: Production Coordinator

Production Planning & Scheduling

Daily / before shift start Production Manager / Coordinator

Production Manager / Coordinator

01Prioritize jobs by promised delivery date, complexity, and strategic importance.
02Group jobs by product type, finish type, or maker skill where efficient.
03Assign estimated start and finish dates per job.
04Allocate makers, stations, and tools to each job.
05Flag dependencies such as drying time, outsourced work, or custom approvals.

Every job must have an owner, target date, and status.

Handoff to: Workshop Supervisor

Work Order Release

Same day as planning approval Production Coordinator

Production Coordinator

Work Order Must Include: Order ID / Job ID · SKU · Quantity & dimensions · Material list & finish spec · Reference image · Special handling notes · Due date · QC checkpoints

01Print or digitally issue the work order with all required fields.
02Attach sample image or design reference where needed.
03Release raw materials from inventory against the job.
04Obtain supervisor acknowledgment of work order receipt.

No verbal-only production for custom or repeat-sensitive items.

Handoff to: Workshop Supervisor / Assigned Maker

Making / Fabrication / Assembly

Per SKU standard Assigned Maker + Workshop Supervisor

Assigned Maker / ArtisanWorkshop Supervisor

Cutting / Shaping Joining / Structuring Surface Prep Detailing Assembly

01Collect issued materials from inventory against work order.
02Start fabrication, crafting, or assembly per approved specifications.
03Maintain stage updates on job card in real time.
04Minimize wastage and record excess loss if any occurs.
05Escalate defects, material shortages, or specification ambiguity immediately to Supervisor.

Any variation from approved spec must be approved before continuing.

Handoff to: In-Process QC / Finishing

In-Process Quality Control

Same shift QC Executive + Workshop Supervisor

QC ExecutiveWorkshop Supervisor

Inspect for:
Correct dimensions · Structural accuracy · Clean workmanship · Alignment / balance · Material consistency · No major defects

Disposition Options:
✓ Pass
⟳ Rework Required
✕ Reject

01Inspect the partially completed unit at the appropriate mid-stage.
02Mark disposition: Pass, Rework Required, or Reject.
03Record issue type and assign rework owner if rework is required.
04Re-inspect and re-record after correction is completed.

No item moves to premium finishing unless structure is approved.

Handoff to: Finishing or Rework

Finishing

Per SKU standard Finishing Team / Assigned Maker / Supervisor

Finishing TeamAssigned MakerSupervisor

01Surface smoothening and cleaning.
02Apply paint, stain, polish, coating, fabric finish, or protective treatment as applicable.
03Attach accessories, pads, hardware, tags, or decorative elements.
04Allow full required drying, settling, or curing time per product standard.
05Protect finished item from dust, scratches, and handling damage during settling.

Premature movement from finishing area is not permitted. Drying time must be planned, not assumed.

Handoff to: Final QC

Final Quality Control

12–24 hrs after finishing QC Executive

QC Executive

Final QC Checklist: ✓ Correct product & quantity · ✓ Correct size & configuration · ✓ Finish quality consistent · ✓ Stable & structurally sound · ✓ No scratches, stains, chips, or loose parts · ✓ Packaging readiness confirmed · ✓ Special custom instructions met

01Check correct product and quantity confirmed against work order.
02Verify no scratches, stains, chips, loose parts, or visual imbalance.
03Confirm packaging readiness and all special custom instructions are met.
04Assign disposition: Pass / Pass with Note / Rework Required / Reject.

QC sign-off is mandatory before packing begins. No exceptions.

Handoff to: Packaging / Fulfillment

Packaging & Labeling

Same day to 24 hrs Packaging & Fulfillment Executive

Packaging & Fulfillment Executive

01Verify approved quantity against dispatch note.
02Select packaging based on fragility, size, value, and transport mode.
03Add protective wraps, corner guards, cushioning, and moisture protection where needed.
04Apply SKU, order, customer, and destination labels accurately.
05Add care card, branding insert, or invoice copy as required.
06Mark as Fragile / Top Load / This Side Up where relevant.

Packed goods must remain traceable to their job/order.

Handoff to: Dispatch Coordinator

Dispatch Readiness Check

Same day before cut-off Dispatch Coordinator + Executive

Dispatch CoordinatorExecutive, Creative Operations

01Verify packed quantity against dispatch note.
02Verify delivery address, route, customer contact, and installation schedule.
03Confirm payment and handover conditions are met.
04Confirm vehicle, courier, or manpower arrangement.
05Prepare delivery challan and handover note.

Nothing ships without approved paperwork and status update.

Handoff to: Delivery / Installation Team

Delivery / Installation Handover

Per dispatch plan Delivery + Installation + Dispatch Coordinator

Delivery TeamInstallation TeamDispatch Coordinator

01Load goods carefully with physical checklist.
02Deliver to customer, project site, showroom, or warehouse.
03Obtain proof of delivery or installation sign-off.
04Report any damage, refusal, delay, or site issues immediately.
05Close delivery status in the production/dispatch tracker.

Proof of delivery is mandatory for closure.

Handoff to: Order Closure / Customer Service / Records

Closure & Record Update

Within 24 hrs of delivery Executive + Order Management / Accounts

Executive, Creative OperationsOrder Management / Accounts / Operations

01Update job status to Completed in the tracker.
02Record actual completion date.
03Record variance from originally promised timeline.
04Record any rework incidents, wastage, or quality issues.
05Update sales, order, inventory, and delivery tracker.
06Flag learning points for process improvement and share in next review.

No order should remain operationally open after completion.

Handoff to: Operations Closed

Category 04 · 2 Items

Quality Control

Quality gates at every stage — intake, in-process, and final. QC controls all movement in the production chain.

Quality Control Checklist

Standardized inspection applied to all finished products

→Visual appearance and surface finish
→Weight accuracy and dimensions
→Scent / texture integrity (candles, spa)
→Labeling completeness and accuracy
→Brand packaging compliance
→Structural integrity — no loose parts

+42

Non-Conformance & Defect Log

+ NEW — RECOMMENDED ADDITION

⚠This document does not currently exist and is a critical gap. QC Checklist identifies issues but there is no log to record, categorize, and track defects for root cause analysis.

Each entry should capture: Batch number · Defect type · Volume affected · Responsible team member · Corrective action taken. Enables trend analysis and continuous improvement.

Category 09 · 4 Items

Culture, Values & Compliance

The BOHO ethos is not decoration — it is the operating system for every action taken in the workshop.

The Ten Workshop Principles

Craft with Care

Every item is handcrafted — your hands shape the brand. Work with patience, precision, and pride. No shortcuts in finishing, polishing, or detailing.

Sustainability First

Measure and log all materials before use. Reduce waste through proper planning. Recycle scraps: fabric to accessories, pottery shards to fillers, wax to remelting.

Quality Over Quantity

Luxury equals quality — every piece must be flawless before dispatch. No chipped pottery, uneven stitches, or weak wicks. QC Lead checks every batch personally.

Consistency in Stock & Orders

Maintain minimum 2–3 units of every product in stock. Orders are always the top priority. Stock levels updated daily in logbook without exception.

Respect for Time

Work begins at 9:30 AM sharp — punctuality is non-negotiable. A delay in one step affects the entire supply chain. Follow daily schedules as briefed every morning.

Clean & Safe Workspace

Workstations kept tidy at all times. Tools returned to designated places after use. Safety protocols mandatory: gloves, masks, and aprons. Fire safety always ready.

Teamwork & Accountability

No task is 'not my job.' Take ownership of your role — if something goes wrong, report it immediately. Transparency prevents misunderstandings and delays.

Innovation & Creativity

Discipline enables creative freedom. Share new design ideas with the Creative Director. Experiment responsibly with eco-materials, natural dyes, and finishes.

Customer in Mind

Every item ends up in a customer's space — treat each one as a gift. Work with empathy: you are shaping someone's lived experience of BOHO.

Live the Brand Ethos

BOHO embodies The Art of Less, Wabi-Sabi, and Slow Living. Simplicity in every decision. Imperfections are embraced as part of genuine craftsmanship.

Workshop Do's & Don'ts

✓ Craftsmanship Do's

Always follow approved designs & prototypes — no personal modifications without approval.
Take time to polish, finish, and QC every piece before placing in storage.
Label all products correctly with product code, date, and artisan initials.
Use proper tools for each material — never improvise with the wrong tool.

✕ Craftsmanship Don'ts

Don't pass any product to storage without QC Lead approval — no exceptions.
Don't ignore defects (cracks, loose stitches, uneven wax) — reject or rework immediately.
Don't skip finishing steps: sanding, glazing, trimming, and polishing are all required.
Don't mix unapproved materials or shortcuts such as plastic fillers or synthetic dyes.

✓ Time & Workflow Do's

Be punctual — work starts at 9:30 AM sharp, every single day.
Complete daily batch targets and record all production in the logbook.
Follow the step-by-step workflow: Raw Material → Production → In-Process QC → Final QC → Inventory.
Respect deadlines — one delay in your step affects the entire order chain.

✕ Time & Workflow Don'ts

Don't arrive late — your delay cascades through everyone's schedule.
Don't leave tasks incomplete without properly handing them over to a colleague.
Don't skip production log entries — undocumented work equals wasted effort.
Don't prioritize personal side projects over your assigned BOHO work.

✓ Sustainability Do's

Use only the allocated quantity of raw materials — measure carefully before use.
Reuse and recycle waste: fabric scraps, clay shards, and wax leftovers all have value.
Segregate eco-waste and non-eco waste into designated bins.
Follow eco-packaging practices — avoid plastic unless absolutely necessary.

✕ Sustainability Don'ts

Don't waste raw materials through over-cutting fabric or discarding usable clay.
Don't dispose of scraps carelessly — all scraps must go to recycling bins.
Don't bring non-eco packaging into the workshop (poly bags, Styrofoam).
Don't waste energy — turn off kilns, heaters, and machines when not in active use.

✓ Safety & Cleanliness Do's

Keep your workstation tidy and organized at all times throughout the day.
Return all tools to their proper racks after every use — no exceptions.
Wear full PPE (gloves, aprons, masks) when working with dyes, wax, or kilns.
Report any accidents, spills, or tool damage immediately to your supervisor.

✕ Safety & Cleanliness Don'ts

Don't leave sharp tools, needles, or cutters lying around unattended.
Don't eat or drink at workstations — this risks spills and product contamination.
Don't leave wax, dyes, or chemicals open or uncovered when not in use.
Don't ignore or skip safety gear — it is mandatory and non-negotiable.

Sustainability Scrap Recycling Flows

Fabric Scraps→ Small Accessories

Pottery Shards→ Fillers

Wax Leftovers→ Remelting

Clay Remnants→ Secondary Pieces

Eco-Waste→ Designated Bins

Compliance Consequences Framework

Behavior	Level	Consequence
Ignoring QC checks or production deadlines	Warning	Formal warning issued
Unauthorized use of workshop materials	Disciplinary	Disciplinary action
Repeated neglect of cleanliness or safety	Penalty	Penalty applied
Ethics & Sustainability Training attendance	Required	Mandatory quarterly — all artisans & staff

KPI

Section 7 · KPI Framework

Key Performance Indicators

8 core KPIs covering production, quality, delivery, and inventory. Each has a defined formula, target, measurement frequency, and owner.

KPI 01

On-Time Production Rate

Jobs completed on/before scheduled date ÷ Total jobs × 100

≥ 90% — Flag if below 80% for 2 consecutive weeks

WeeklyProduction Coordinator

KPI 02

On-Time Delivery Readiness

Orders ready on/before committed dispatch date ÷ Total orders × 100

≥ 92% — Investigate every case below threshold

Weekly / Per BatchExecutive + Dispatch

KPI 03

Rework Percentage

Units sent to rework ÷ Total units produced × 100

≤ 8% overall · ≤ 5% repeat SKUs · Alert if any SKU exceeds 15%

Weekly + MonthlyQC + Workshop Supervisor

KPI 04

QC First-Pass Rate

Units passing QC on first attempt ÷ Total units inspected × 100

≥ 85% first-pass at Final QC · Below 75% requires immediate RCA

WeeklyQC Executive

KPI 05

Material Shortage Incidents

Count of jobs delayed due to material unavailability at scheduled start

≤ 2 incidents / month · Zero tolerance for repeat shortages on same material

Monthly (per incident)Procurement / Inventory

KPI 06

Average Job Cycle Time

Sum of (Final QC Pass Date − Work Order Release Date) ÷ Number of jobs

Must be defined per SKU category. Review monthly to establish baselines.

Monthly per SKUProduction Coordinator

KPI 07

Packaging Error Rate

Orders with packaging errors ÷ Total orders packed × 100

≤ 2% · Zero tolerance for wrong-label or wrong-customer errors

Per Batch / WeeklyPackaging Executive

KPI 08

Damage-on-Delivery Rate

Deliveries with reported damage ÷ Total deliveries made × 100

≤ 1% · Above 2% triggers packaging and logistics review

MonthlyDispatch + Delivery Team

Traffic Light Scoring System

GREEN — On Target

At or above target — performing well.
Action: Maintain and monitor.

AMBER — Watch Zone

5–10% below target — needs attention.
Action: Identify root cause. Escalate if no improvement in 2 weeks.

RED — Critical Failure

More than 10% below target — immediate action.
Action: RCA required. Corrective action with owner and deadline.

Final Reference Document

Master Execution
Checklist

Use this checklist to verify, execute, and implement the complete BOHO ALTA production process. Check each item as completed. This is your daily and stage-by-stage operational reference.

Stage 01–02

Order Receipt & Production Trigger

Order confirmed — payment / approval status verified

Product specifications complete — SKU, qty, dimensions, finish, delivery date

Production brief created and sent to Production Coordinator

Bill of materials reviewed — primary, accessories, finishing, packaging

Available stock checked and reserved against the production order

Shortages identified — procurement raised if required before planning proceeds

Stage 03–04

Raw Material Intake & Inspection

Material received from vendor / internal transfer

Quantity matched against purchase order / requisition

Receipt logged — date, vendor, quantity, reference number recorded

Material labeled and segregated by category

QC inspection complete — checked for defects, color mismatch, warping, dimensions

Material categorized as Approved / Conditional / Rejected

Rejected material isolated physically and vendor follow-up logged

Approved items stored in designated zones; fragile items tagged

Stage 05–06

Production Planning & Work Order Release

Jobs prioritized by promised date, complexity, and strategic importance

Jobs grouped by product type, finish type, or maker skill

Start and finish dates assigned per job

Makers, stations, and tools allocated to each job

Dependencies flagged — drying time, outsourced work, custom approvals

Work order issued — includes Order ID, SKU, qty, dimensions, material list, finish spec, due date

Reference image attached where needed

Raw materials released from inventory; supervisor acknowledged receipt

Stage 07–09

Making, In-Process QC & Finishing

Materials collected from inventory against work order

Fabrication started per approved specifications only

Stage updates maintained on job card in real time

Wastage minimized and excess loss recorded

In-process QC conducted — dimensions, structure, workmanship, alignment checked

Disposition marked — Pass / Rework / Reject. Rework owner assigned and logged.

Item approved for finishing — structure sign-off obtained

Finishing applied — surface prep, paint/coat/polish, accessories attached

Drying / curing time honored — no premature movement from finishing area

Finished item protected from dust, scratches, and handling damage

Stage 10

Final Quality Control

Correct product and quantity confirmed against work order

Correct size and configuration verified

Finish quality consistent and meets BOHO ALTA standard

Structurally stable — no loose parts, chips, or imbalance

No surface defects — no scratches, stains, or visual inconsistencies

Special custom instructions fully met

QC sign-off obtained — written / digital approval before packing begins

Disposition assigned — Pass / Pass with Note / Rework / Reject

Stage 11–12

Packaging, Labeling & Dispatch Readiness

Approved quantity verified against dispatch note

Packaging selected based on fragility, size, value, and transport mode

Protective wraps applied — corner guards, cushioning, moisture protection

Labels applied accurately — SKU, order, customer, and destination

Care card / branding insert / invoice included as required

Handling marks applied — Fragile / Top Load / This Side Up

Delivery address, route, and contact verified

Payment and handover conditions confirmed

Vehicle / courier / manpower confirmed and ready

Delivery challan and handover note prepared and approved

Stage 13–14

Delivery, Handover & Closure

Goods loaded carefully with physical loading checklist

Delivered to correct destination — customer / project site / showroom / warehouse

Proof of delivery obtained — signed POD or installation sign-off

Any damage, refusal, or delay reported immediately and logged

Delivery status closed in the production/dispatch tracker

Job status updated to Completed in tracker

Actual completion date recorded and variance from promised timeline noted

Rework, wastage, quality incidents recorded

All trackers updated — sales, order, inventory, and delivery

Learning points flagged for process improvement in next review

Daily

Culture & Workshop Compliance

Work started at 9:30 AM — morning briefing attended

Workstation clean and organized before production begins

PPE worn at all hazardous stations (dyes, wax, kilns)

Daily batch targets logged in production logbook

Material usage measured before use; wastage logged

Scraps segregated into correct recycling bins

Tools returned to proper racks after every use

Issues and defects reported immediately — no hidden mistakes

Audit

Process Audit Checklist

Documentation

Complete production brief present for every active job?

Valid work order issued for every job on the floor?

All material receipts recorded with vendor, date, quantity?

QC approvals traceable to each unit and job?

Proof of delivery stored for all completed deliveries?

Rework cases logged with reason, owner, and revised date?

Operations

Time targets being consistently met across all stages?

Rework cases being recorded systematically?

Workshop allocation balanced across makers and skills?

Stock reservations accurate and updated in real time?

Rejected materials physically isolated and labeled?

Top recurring defects reviewed and root cause identified?

Performance Management

KPI Compliance Tracker

Track, measure, and score all 8 KPIs across the BOHO ALTA production framework. Use the traffic light system to signal performance. Complete the compliance column after each measurement cycle.

Green Zone

At or Above Target

Maintain and monitor

Amber Zone

5–10% Below Target

Identify root cause. Escalate in 2 weeks.

Red Zone

>10% Below Target

Immediate RCA required

#	KPI Name & Owner	Formula	Target	Frequency	Current Score	Compliant?	Action Required
01	On-Time Production Rate Production Coordinator	Jobs on-time ÷ Total jobs × 100	≥ 90% Flag <80% × 2 weeks	Weekly	___%	Yes No	___________________
02	On-Time Delivery Readiness Executive + Dispatch Coordinator	Orders ready on-time ÷ Total dispatched × 100	≥ 92% Investigate every miss	Weekly / Per batch	___%	Yes No	___________________
03	Rework Percentage QC Executive + Workshop Supervisor	Units reworked ÷ Total produced × 100	≤ 8% overall Alert if SKU >15%	Weekly + Monthly trend	___%	Yes No	___________________
04	QC First-Pass Rate QC Executive	Units passing first QC ÷ Total inspected × 100	≥ 85% Below 75% → immediate RCA	Weekly	___%	Yes No	___________________
05	Material Shortage Incidents Procurement / Inventory Executive	Count of jobs blocked by material shortage	≤ 2 / month Zero tolerance repeats	Monthly (per incident)	___ incidents	Yes No	___________________
06	Average Job Cycle Time Production Coordinator	Sum (QC Pass – WO Release) ÷ Jobs	Per SKU baseline Review monthly to refine	Monthly per SKU	___ days avg	Yes No	___________________
07	Packaging Error Rate Packaging & Fulfillment Executive	Orders with errors ÷ Total packed × 100	≤ 2% Zero for wrong-label errors	Per batch / Weekly	___%	Yes No	___________________
08	Damage-on-Delivery Rate Dispatch Coordinator + Delivery Team	Deliveries with damage ÷ Total deliveries × 100	≤ 1% Above 2% → logistics review	Monthly	___%	Yes No	___________________

Root Cause Analysis (RCA) Template — For Any RED KPI

WHAT

Which KPI? Which period? By how much was it off target?

WHERE

Which stage(s) in the workflow contributed to the failure?

WHY × 5

Ask 'Why' five times to drill to the root cause, not the symptom.

WHAT WILL WE CHANGE

Specific corrective action with an owner and a deadline.

WHO / BY WHEN

Named owner. Specific deadline. Written and shared with team.

HOW CONFIRMED

Monitor 2–4 weeks. Verify KPI returns to green before closing RCA.

KPI Review Cadence

Daily

Production Coordinator reviews job completion status and flags any delays vs plan

Weekly

On-Time Rate · Rework % · QC First-Pass · Packaging Errors

Monthly

Full KPI review with all owners. Review trend lines, not just point-in-time values.

Quarterly

Strategic review. Revise targets if baselines shift. Update SKU cycle time standards.