Plant-wide signals for the loaded production window — output, consumption, fleet availability.
The plant ran 1,649.5 hours and lost 525.5 hours to downtime, leaving availability at 75.8%. That means 61,575 units were produced across 95 runs, but a quarter of scheduled time was unavailable.
Low availability directly caps output and increases schedule pressure on the remaining run time.
Unspecified downtime accounts for 551 hours across 48 events on 14 machines. The next largest reasons are No Plan at 12 hours, Dye Change at 9 hours, and Heat Check at 6 hours.
Most downtime is not being classified clearly, which makes root-cause elimination and maintenance planning much harder.
This run used 1,163.347 kg against 120 kg expected, a variance of 1,043.347 kg. That is an 8.69x overage on RM2820 for FG7210.
Large material overconsumption can erase margin quickly and may indicate scrap, setup loss, or master-data issues.
The run for FG7223 consumed 14.34 kg of RM2044 versus 0.15 kg expected. That is a 94.6% variance on a single run of 2,400 units.
A near-total mismatch between actual and expected input usually signals BOM, reporting, or process execution errors.
Shift A delivered 24,763 units, while Shift B recorded 0 units across 10 documents. Total output came from 56 BOTH-shift runs plus A-shift activity.
A zero-output shift can mean labor, planning, or data-capture gaps that distort true capacity and staffing performance.
LSP100 posted 95.4% availability over 435 run hours with only 21 downtime hours across 19 docs. SJ-60/36-20 was also strong at 92.6% availability.
These machines show the operating pattern to replicate on weaker assets and protect throughput.