Plant Overview

Shift B · Aug 11, 2026 · 21:40

Plant is running 6.4% behind plan. Two machines are down on Line 02 and Line 03 — together they explain 78% of the shortfall.

Investigate losses

Production

-580 units

8,420/ 9,000 units

Target 9,000 units6.4% behind shift plan

OEE

-6.6 pts

78.4%

Target 85.0%Availability is the main drag

Yield

-0.7 pts

96.8%

Target 97.5%Line 02 pulling the average down

Scrap

+0.7 pts

3.2%

Target 2.5%268 units scrapped this shift

Downtime

+26 min

71min

Target 45 min4 unplanned stops

Cycle Time

+1.6 sec

42.6sec

Target 41.0 secMachine 07 running slow

Production Performance

Cumulative actual vs target — the gap opens at 18:00

Full breakdown

Production by hour

Actual vs planned by line

Line 013,120 / 3,000

Line 022,480 / 3,000

Line 032,820 / 3,000

Top Losses

Ranked by downtime, with lost units and cost

All events

Machine 04 — Tool Change

Line 02 · 18:12–18:43

31min

142 units lost$3,550 estimated impact

Machine 07 — Material Jam

Line 03 · 19:04–19:26

22min

101 units lost$2,525 estimated impact

Machine 02 — Sensor Failure

Line 01 · 16:38–16:49

11min

50 units lost$1,250 estimated impact

Machine 05 — Quality Hold

Line 02 · 20:10–20:17

7min

32 units lost$800 estimated impact

Total loss impact today

$8,125

325 units lost · $4,180 scrap cost · $6,300 recoverable

Equipment Status

7 assets · 2 down · 1 idle

Asset matrix

Machine 01

RUNNING

OEE: 88.2%
Cycle: 40.8s
Down: 4m
Units: 1,580

Machine 02

RUNNING

OEE: 82.7%
Cycle: 41.9s
Down: 11m
Units: 1,540

Machine 03

IDLE

OEE: 64.1%
Cycle: 43.4s
Down: 18m
Units: 1,210

Machine 04

DOWN

OEE: 51.3%
Cycle: 48.2s
Down: 31m
Units: 980

Machine 05

RUNNING

OEE: 84.5%
Cycle: 42.1s
Down: 7m
Units: 1,500

Machine 06

RUNNING

OEE: 86.9%
Cycle: 41.2s
Down: 5m
Units: 1,560

Machine 07

DOWN

OEE: 58.4%
Cycle: 46.7s
Down: 22m
Units: 1,050

Alert Center

Areas needing immediate attention

Open center

CRITICAL · 18:12

Machine 04 has been down for 31 minutes

Tool change on spindle 2 exceeded standard by 19 min. Line 02 output stopped since 18:12.

CRITICAL · 19:04

Machine 07 material jam blocking packaging

Infeed conveyor jam detected by photo-eye PE-14. Operator intervention in progress.

WARNING · 18:45

Line 02 yield is 3.2% below target

First pass yield dropped to 94.3% after 18:00. Torque station variance rising.

WARNING · 19:30

Defect rate increased 18% during Shift B

Torque Out of Spec is the dominant defect (96 occurrences, 35.8% of total).

WARNING · 20:02

Machine 03 idle for 18 minutes

Starved by upstream buffer. Material handler notified at 20:02.