Job status lives on whiteboards and spreadsheets. By the time a delay surfaces, the customer has already been let down and the machine has sat idle for hours.
Every work order, machine and material feeds one live board. Bottlenecks and at-risk orders flag themselves in real time so you act before the due date, not after.
AI Insights — Today
Production Output — Planned vs Actual (this week)
Units / dayShop-Floor Status
Today's Schedule
| Work Order | Product | Qty | Stage | Due |
|---|---|---|---|---|
| WO-2411 | Brake caliper — front | 500 | Machining | Today 16:00 |
| WO-2408 | Suspension bracket L | 1,200 | Cutting | At risk |
| WO-2414 | Gearbox mount plate | 340 | Assembly | Fri 26 Sep |
| WO-2415 | Exhaust flange ring | 800 | Quality | Fri 26 Sep |
| WO-2417 | Steering knuckle | 220 | Queued | Mon 29 Sep |
| WO-2419 | Pulley hub — 6in | 640 | Machining | Mon 29 Sep |
| WO-2421 | Clutch pressure plate | 300 | Ready to ship | Today 18:00 |
Action Required
3Supervisors chase job cards across six departments; nobody knows what is genuinely next or which order is quietly slipping.
One Kanban from cutting to dispatch. Progress bars, operators and due dates update as jobs are scanned through each work centre.
Machines stop and nobody logs why. Losses to small stops, changeovers and scrap disappear into "that's just how it runs".
Every stop is captured with a reason code. OEE is broken into A/P/Q so you know whether to fix uptime, speed or scrap first.
Predictive Maintenance
CNC Lathe #1
RunningCNC Lathe #2
DownPress Brake A
RunningVMC Machining Ctr
RunningPowder Coat Line
IdleWelding Bay 3
RunningDowntime Log — Today
2h 58m total| Machine | Reason | Duration | Operator | Time |
|---|---|---|---|---|
| CNC Lathe #2 | Breakdown — spindle | 48 min | Amit Kulkarni | 11:42 |
| Powder Coat Line | Changeover | 22 min | Sneha Deshpande | 10:15 |
| Press Brake A | Tool change | 18 min | Jayesh Pawar | 09:30 |
| VMC Machining Ctr | Material wait | 31 min | Manoj Kadam | 08:50 |
| Welding Bay 3 | No operator | 15 min | — | 08:05 |
| CNC Lathe #1 | Setup / first-off | 26 min | Amit Kulkarni | 07:20 |
| Powder Coat Line | Cleaning | 18 min | Sneha Deshpande | 06:45 |
Downtime Reasons — 7-day
Raw Material Stock
| Material | SKU | On Hand | Reorder Pt | Status | |
|---|---|---|---|---|---|
| Steel bar 4140 · Ø42mm | SKU-STL-4140 | 180 kg | 640 kg | Below reorder | |
| Aluminium ingot 6061 | SKU-ALU-6061 | 1,240 kg | 500 kg | In stock | |
| CI casting blank — caliper | SKU-CST-CAL | 320 pcs | 400 pcs | Low | |
| MS sheet 3mm · 1250×2500 | SKU-MS-3MM | 84 sheets | 40 sheets | In stock | |
| Powder coat — RAL 9005 | SKU-PWD-9005 | 0 kg | 50 kg | Out of stock | |
| M10 hex bolt · Gr 8.8 | SKU-FST-M10 | 9,600 pcs | 5,000 pcs | In stock | |
| Brake seal kit | SKU-SEL-BRK | 160 sets | 300 sets | Low | |
| Cutting fluid — synthetic | SKU-FLD-SYN | 420 L | 150 L | In stock |
Reorder Suggestions
AI forecast4BOM — Brake Caliper Assembly
SKU-BRK-118| Component | Qty / unit |
|---|---|
| CI caliper body | 1 |
| Piston Ø38mm | 2 |
| Brake seal kit | 1 set |
| Bleed nipple | 1 |
| M10 hex bolt Gr 8.8 | 4 |
| Dust boot | 2 |
Quotes take days, get priced from memory, and the margin only becomes clear after the job ships — sometimes at a loss.
The quote builder pulls material, labour and machine rates live, applies your target margin, and shows the true price in seconds.
Quotes & Sales Orders
| Ref | Customer | Product | Qty | Value | Status |
|---|---|---|---|---|---|
| QT-0912 | Meridian Auto Components | Brake caliper front | 2,000 | ₹6.40L | Sent |
| QT-0908 | Ketan Fabrication Works | Pulley hub 6in | 1,500 | ₹3.75L | Won |
| SO-2214 | Nashik Motors Pvt Ltd | Cam lever arm | 4,000 | ₹9.20L | In Production |
| QT-0905 | Deccan Silencers | Exhaust flange ring | 3,200 | ₹4.16L | Draft |
| SO-2210 | Pune Tractors Ltd | Engine mount | 2,500 | ₹7.50L | In Production |
| QT-0901 | Aurangabad Gears | Gearbox mount plate | 1,000 | ₹2.90L | Lost |
| QT-0898 | Sahyadri Castings | Steering knuckle | 900 | ₹5.31L | Sent |
| SO-2205 | Meridian Auto Components | Suspension bracket L | 6,000 | ₹8.40L | Won |
Instant Quote Builder
Pulley hub 6inRejects are found at final inspection, or worse, by the customer. Nobody links defects back to the machine, batch or shift that caused them.
In-line checks log pass/fail per operation, raise NCRs automatically and trace every defect to its source so it stops recurring.
Defect Rate Trend (weekly %)
Trending downPass / Fail by Product
Non-Conformance Reports (NCR) Log
| NCR | Product | Defect Type | Qty | Severity | Status | Owner |
|---|---|---|---|---|---|---|
| NCR-341 | Exhaust flange ring | Weld porosity | 42 | Critical | In review | Priya Nair |
| NCR-340 | Suspension bracket L | Dimensional — hole pitch | 28 | Major | Rework | Manoj Kadam |
| NCR-338 | Brake caliper front | Surface finish | 11 | Minor | Closed | Amit Kulkarni |
| NCR-337 | Cam lever arm | Burr — deburr miss | 64 | Major | Rework | Rohit Verma |
| NCR-335 | Gearbox mount plate | Coating adhesion | 19 | Minor | In review | Sneha Deshpande |
| NCR-333 | Pulley hub 6in | Bore oversize | 7 | Major | Closed | Manoj Kadam |
| NCR-331 | Engine mount | Missing bracket tab | 15 | Critical | Closed | Rohit Verma |
Defect Categories — MTD
Month-end means one person exporting spreadsheets for two days, and by then the trends are already history.
Every report is live off the same data the floor generates. Filter, drill in and export — no reconciliation, no waiting.
On-Time Delivery Trend (monthly %)
▲ 3.1%Capacity Utilization by Work Centre
Top Products by Volume (MTD)
| Product | SKU | Units | Revenue | On-Time |
|---|---|---|---|---|
| Suspension bracket L | SKU-SUS-118 | 6,000 | ₹8.40L | 98% |
| Cam lever arm | SKU-CAM-077 | 4,000 | ₹9.20L | 96% |
| Engine mount | SKU-MNT-014 | 2,500 | ₹7.50L | 99% |
| Brake caliper front | SKU-BRK-118 | 2,000 | ₹6.40L | 91% |
| Pulley hub 6in | SKU-HUB-006 | 1,500 | ₹4.27L | 95% |
| Exhaust flange ring | SKU-RNG-802 | 1,280 | ₹1.66L | 87% |
Delivery Summary
Delivery Delay Prediction
Weighs machine load, upstream WIP and material availability to warn you which orders slip — with days of notice, not hours.
Delays surface at the due date, after the customer has already been let down.
Predicts finish dates per WO from live load and material feeds; flags WO-2408 at 87% risk.
Raises an alert, proposes overtime or re-routing, and notifies the account owner.
Lifts on-time delivery past 94% and protects at-risk revenue.
Predictive Maintenance
Learns each machine's normal downtime and vibration signature and warns when an asset is drifting toward breakdown.
CNC Lathe #2 overheats mid-shift and takes two orders down with it.
Detects the rising vibration/temperature pattern days ahead and estimates time-to-failure.
Opens a maintenance WO, reserves the part and books a low-load window.
Cuts unplanned downtime — the biggest OEE loss at 34% — toward the 85% target.
Smart Material Forecasting & Auto-Reorder
Reads the production plan and BOMs to project material burn, then drafts POs against the right supplier and lead time.
Steel bar 4140 hits zero mid-week and stalls WO-2417 with no PO in flight.
Projects a stockout in 4 days at current burn and sizes a 1,000 kg reorder with buffer.
Drafts a PO to Bharat Steels for one-click approval and tracks it to receipt.
Ends material-wait downtime (18% of stops) without over-stocking cash.
RFQ-to-Quote Automation
Extracts part, material, quantity and tolerance from an inbound RFQ, then prices it live from your cost model.
Quotes take days, get priced from memory, and margins only appear after shipping.
Parses the email and drawing, matches the part and applies live material and machine rates.
Generates a costed quote at your target margin, ready to review and send.
Turns days-long quoting into minutes and lifts the 38% win rate.
Quality Anomaly Detection
Monitors first-pass yield per operation and correlates a spike back to the machine, batch or shift behind it.
Weld porosity on exhaust flange rings surfaces only at final inspection.
Spots the yield drop to 89.4% early and traces it to Welding Bay 3 parameters.
Raises an NCR, quarantines the batch and alerts the QC owner with the likely cause.
Shrinks the ₹3.25L cost of quality and stops defects recurring.
Daily AI Production Briefing
Compiles output vs plan, the day's issues and tomorrow's risks into a plain-language briefing for the morning review.
The plant manager stitches the shift picture together from whiteboards each morning.
Summarises attainment (86% this week), downtime and the at-risk orders for tomorrow.
Delivers the briefing to WhatsApp and email at shift end, every day.
Saves the supervisor an hour a day and keeps everyone on the same truth.
Document AI — RFQ → Draft Quote
Inbound RFQ
EmailHi Rahul,
Please quote for our front brake caliper as per attached drawing MAC-BRK-118 Rev C. Casting in grey cast iron GG25, machined per drawing. We need 2,000 pcs with first delivery by 18 October 2026. Bore tolerance H7 is critical. Kindly share landed price per unit.
Regards,
Meridian Auto Components — Purchasing