Shift A is leading output
Shift A produced 100% more units than the other shift over the period.
Impact100% gap
Persistent shift imbalances usually point to operator skill, machine assignment, or schedule mix — not capacity.
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. 3 signals need attention this period — roughly OMR 6,390 of material cost is at risk.
Unspecified accounts for 95% of all downtime (551.0 h across 14 machines).
Concentrating fixes on the top Pareto reason typically returns more uptime than spreading effort thin.
Availability 38% with 30.0 h downtime across 2 production runs.
Sub-70% availability is a recurring-failure or scheduling signal, not random noise. Worth a maintenance review.
Production used 27662.5 kg more than BOM expected across the period.
Sustained overconsumption inflates unit cost and erodes margin even when output looks normal.
Shift A produced 100% more units than the other shift over the period.
Persistent shift imbalances usually point to operator skill, machine assignment, or schedule mix — not capacity.
Availability 38% with 30.0 h downtime across 2 production runs.
Sub-70% availability is a recurring-failure or scheduling signal, not random noise. Worth a maintenance review.
100% availability over 1 production runs — model this machine's schedule for the others.
Use this machine's run pattern as the template when re-balancing the rest of the floor.
Unspecified accounts for 95% of all downtime (551.0 h across 14 machines).
Concentrating fixes on the top Pareto reason typically returns more uptime than spreading effort thin.
Production used 27662.5 kg more than BOM expected across the period.
Sustained overconsumption inflates unit cost and erodes margin even when output looks normal.
Materials were consumed that aren't listed in the BOM for the finished good. Either the BOM is stale, or substitutions are happening on the floor.
Off-BOM substitutions hide real material cost from the standard recipe and break costing rollups downstream.