ModulesDiagnostic
Plant-Floor Diagnostic Engine
v3.2.1Plant code: PLT-DFW-014
Lines: 3 (Press Shop, Stamping, Assembly)
Telemetry source: OPC-UA bridge (via certified integration partner)
Calibration date: 2026-02-08
Calibration owner: Jonathas de Oliveira da Cruz
Live OEE — last 8 hours
Floor line at 70% (red dashed). Root-cause engine fires when severity-weighted dip crosses threshold.
Active root-cause findings
Rule TPS-027Critical
Severity-weighted OEE dip on Press Shop correlated to upstream feed variability (mura signature)
Recommended countermeasure: Stabilize feed-roller dwell window; A3 template TPS-027-CM01
Rule TPS-048High
QC visual-inspection escape rate trending above 1.2% — defect cluster on stamped panel B-14
Recommended countermeasure: Insert 100% torque-check at station 4; brief on JI-3 pattern
Rule TPS-021High
Mura signature in stamping feed — variance above 8% across last 4 shifts
Recommended countermeasure: Re-baseline feed-roller setup per JM-2 standardized work
Rule TPS-072Medium
Motion waste on Assembly Line 2 — operator travel measured at 16.4 m/cycle (target 14 m)
Recommended countermeasure: Re-layout small-parts kanban shelf; A3 template TPS-072-CM03
| Rule ID | Title | Category | Severity weighting | Last refined |
|---|---|---|---|---|
| TPS-014 | Severity-weighted OEE dip — single-line | muda | 0.78 | 2026-04-12 |
| TPS-021 | Mura signature — feed variability upstream of stamping | mura | 0.91 | 2026-04-12 |
| TPS-027 | Press-shop tool-change overrun threshold | muda | 0.84 | 2026-03-30 |
| TPS-033 | Overproduction trigger — buffer stock > 1.5x takt | muda | 0.62 | 2026-03-30 |
| TPS-041 | Muri detection — operator overburden by station-cycle ratio | muri | 0.74 | 2026-02-08 |
| TPS-048 | Defect cluster — QC visual-inspection escape rate | muda | 0.88 | 2026-04-12 |
| TPS-053 | Waiting waste — line-feed starvation correlation | muda | 0.69 | 2026-02-08 |
| TPS-061 | Mura — shift-to-shift output variance > 8% | mura | 0.81 | 2026-03-30 |
| TPS-067 | Overprocessing — duplicate inspection step in QC | muda | 0.55 | 2026-04-12 |
| TPS-072 | Motion waste — operator travel > 14 m per cycle | muda | 0.66 | 2026-02-08 |
| TPS-079 | Muri — overtime concentration on single operator group | muri | 0.77 | 2026-03-30 |
| TPS-084 | Inventory — WIP queue between Press and Stamping | muda | 0.72 | 2026-04-12 |
Rule library authored by Jonathas de Oliveira da Cruz. Updates ship quarterly under the codified change-management protocol.