Cross-signal anomaly detection across production, OEE, downtime, and BOM variance — surfacing the runs, machines, and materials that need attention this period.
AI analyzed 95 production runs across 17 machines and 18 finished goods, covering 2,175 h of shift time. 6 signals need attention this period — roughly OMR 6,390 of material cost is at risk.
Unspecified downtime accounts for 551 hours across 48 events on 14 machines. Planned causes were minor by comparison: 12 h No Plan, 9 h Dye Change, and 6 h Heat Check.
Most downtime is not being classified, which makes root-cause action and maintenance prioritization difficult.
Production run DPE2026011764 used 1,163.347 kg vs 120 kg expected, a variance of 1,043.347 kg on 6 units. Another run, DPE2026011041, was 262.956 kg over expected on 945 units.
Large material overruns directly inflate cost and may indicate scrap, setup loss, or BOM/process mismatch.
Production run DPE2026011879 recorded OMR 2,165.896 actual cost against 0 expected cost, and DPE2026011668 added another OMR 1,191.637 over zero expected.
Zero expected cost on active runs suggests master-data or routing setup errors that can distort margin reporting.
The plant produced 61,575 units across 95 production runs, but 525.5 down hours reduced availability to 75.8%.
Low availability is the main limiter on output and points to a large reliability or scheduling issue.
Unspecified downtime accounts for 551 hours across 48 events on 14 machines. Planned causes were minor by comparison: 12 h No Plan, 9 h Dye Change, and 6 h Heat Check.
Most downtime is not being classified, which makes root-cause action and maintenance prioritization difficult.
Shift A produced 24,763 units, while Shift B shows 0 units in the shift summary and 10 docs. Total output came mainly from BOTH-shift runs at 36,812 units.
A zero-output shift signal usually indicates reporting gaps or severe shift imbalance that can hide real capacity issues.
Production run DPE2026011764 used 1,163.347 kg vs 120 kg expected, a variance of 1,043.347 kg on 6 units. Another run, DPE2026011041, was 262.956 kg over expected on 945 units.
Large material overruns directly inflate cost and may indicate scrap, setup loss, or BOM/process mismatch.
Production run DPE2026011879 recorded OMR 2,165.896 actual cost against 0 expected cost, and DPE2026011668 added another OMR 1,191.637 over zero expected.
Zero expected cost on active runs suggests master-data or routing setup errors that can distort margin reporting.
APEX-7 ran 58 h with 58 h down time, and APEX - 1 ran 28 h with 28 h down time. APEX - 1 also ran below standard cavity performance at 88.9%.
These machines are consuming capacity without delivering proportional output, so they are prime candidates for troubleshooting.