Plant-wide signals for the loaded production window — output, consumption, fleet availability.
The plant produced 61,575 units across 95 runs, but 525.5 downtime hours pulled availability down to 75.8%. Run time was 1,649.5 hours versus 525.5 hours down.
Low availability reduces throughput and increases cost per unit because machines spend too much time unavailable.
Unspecified downtime accounts for 551 hours across 48 events on 14 machines. The next largest named losses are No Plan at 12 hours and Dye Change at 9 hours.
When most downtime is uncategorized, it is hard to target the real root causes and recover capacity.
Shift A delivered 43,169 units, while Shift B shows 18,406 units in total but 0 units in the shift summary and 10 docs. This suggests a reporting or execution gap on B shift.
A shift-level mismatch can hide lost production and distort labor and machine planning.
Production run DPE2026011041 on APEX-1 made 945 units of 1 Ltr J/Can Shell Yellow PCR. The machine posted only 44.4% OEE with 28 run hours and 28 down hours.
Poor OEE on a high-volume mold directly limits output on one of the top-selling finished goods.
Across 623 variance rows, 104 were off-bom and total over-consumption reached 27,662.5 kg versus only 1,844.0 kg under. The largest single variance was production run DPE2026011764 at +1,043.3 kg.
Excess input usage drives scrap, cost overruns, and can indicate process or BOM discipline issues.
FG7172 led output with 19,845 units across 6 runs, followed by FG7216 at 14,000 units across 4 runs. Together they represent 33,845 units, or 55% of total production.
Concentrated volume means uptime and material control on these SKUs will have the biggest business effect.