SGRID - Enterprise Smart Factory OEE & SPC

REAL-TIME PLANT OEE SHIFT: 06:00 - 14:00

0% PLANT OEE

Availability 92.4%

Performance 88.7%

Quality 99.1%

RELIABILITY & PRODUCTIVITY METRICS

MTBF 4.2%

142 Hrs

Mean Time Between Failures

MTTR -1.5%

45 Mins

Mean Time To Repair

PRODUCTIVITY 8.1%

1,234 U/Hr

Current Output Rate

NOF -2

12 Stops

Number of Failures

NMS +1

90 Stops

Micro-Stops (< 5m)

MTBF VS MTTR TREND

DOWNTIME CAUSES ANALYSIS

LINE STATUS MATRIX

LINE	MTBF	STATUS
Line M1 OEE 94.8%	180h	RUNNING
Line A1 OEE 87.9%	145h	RUNNING
Line A2 OEE 71.0%	62h	WARNING
Pack Z OEE 45.2%	12h	DOWN

PREDICTIVE INSIGHTS

Line A1 Motor Temp High

85% probability of failure in 4 hrs due to vibration.

GENERATE WORK ORDER

Speed Optimization

Reducing filler speed by 3% can improve OEE by +1.5%.

APPLY ADJUSTMENT

ESG & RESOURCES

Power Limit 4,210 / 5,000 kW

Pneumatic PSI 111 / 120 PSI

Active W.O

24

Scheduled for this week

Capacity Util

88.5%

Target: > 85.0%

On-Time Delivery

96.2%

Based on schedule compliance

Material Risk

2

WO pending raw materials

Master Production Schedule (Gantt)

Running Planned Maintenance

Machine / Line

Mon, 23 Feb

Tue, 24 Feb

Wed, 25 Feb

Thu, 26 Feb

Fri, 27 Feb

Sat, 28 Feb

Sun, 01 Mar

Line M1 (CNC)

WO-091 (Alpha V2)

PM Setup

WO-095 (Beta Gen)

Line A1 (Asm)

WO-088 (Widget X)

WO-092 (Widget Y)

Pack Z

WO-088 Pack

Wait Material

Work Order Queue

WO Number	Product / SKU	Target Qty	Assigned Line	Status
WO-2026-091	Widget Alpha V2	5,000	Line M1	In Progress
WO-2026-088	Widget X	12,000	Line A1	In Progress
WO-2026-095	Beta Gen Motor	8,500	Line M1	Planned
WO-2026-098	Packaging Box C	20,000	Pack Z	Material Hold

Scan / Enter Serial Number (SN) or Batch ID

Product Identity

SN-99823100

Product NameWidget Alpha V2

SKU CodePRD-ALPHA-V2

Work OrderWO-2026-091

Production Date19 Feb 2026

Final QC Status PASSED

Production Journey (Track & Trace)

1. Material Infeed08:15:02

Lot: MAT-PLST-0992 | Supplier: Global Plastindo

2. Machining Process08:18:30

Machine: MCH-004 | Opr: Sistem Otomatis

3. Assembly08:20:45

Machine: MCH-001 | Cycle: 12.1s | Opr: Budi S.

4. Vision QC Check08:21:10

Camera: QC-Cam-01 | Match 99.8% Tolerance

Assembled Bill of Materials (BOM)

Part No	Description	Batch/Lot
P-101	Housing Base	LOT-A99
P-105	Main Gear	LOT-B12
P-202	Sensor Chip	LOT-X01
C-001	Screw Pack (x4)	N/A

OEE Loss Waterfall (Efficiency Bridge)

100%75%50%25%0%

100%

Planned Time

-15%

Downtime Loss

85%

Net Operating Time

-10%

Speed Loss

75%

Net Run Time

-5%

Quality Loss

70%

Final OEE

OEE by Shift (Today)

100%75%50%25%0%

Shift 1

Shift 2

Shift 3

Defect & Scrap Pareto Analysis

Defect Category	Occurrence	Cumulative %	Est. Cost Impact (IDR)
1. Dimension Out-of-Spec	1,240	45.0%	Rp 12.400.000
2. Surface Scratches	850	75.0%	Rp 8.500.000
3. Assembly Misalignment	420	90.0%	Rp 4.200.000
4. Others / Unknown	276	100.0%	Rp 2.760.000

Cp (Capability)

1.45

Process Potential > 1.33 (Good)

Cpk (Index)

1.12

Mean Shift Detected

Sigma Level

4.2 σ

World Class Target: 6.0

DPMO

3,400

Defects Per Million Opportunities

X-Bar Chart (Sample Mean)

UCL: 15.05 CL: 15.00 LCL: 14.95

15.1015.0515.0014.9514.90

S1S2S3S4S5S6S7S8S9S10

Inspection Log Entry

Manually log measurements for Subgroup S11. Parameter: Pin Diameter.

Sample 1

Sample 2

Sample 3

Mean: 0.00

Out of Control Events (Nelson Rules Violation)

Time	Subgroup	Rule Violated	Description	Status	Action
09:45 AM	S8	Rule 1	1 point is more than 3 standard deviations from the mean (Above UCL).	Unresolved
08:10 AM	S7	Rule 3	6 (or more) points in a row are continually increasing (Trend detected).	Investigated

Edge Vision AI (QC)

LIVE

Scratch 98%

Model: ResNet-50 v2 Inference: 12ms

Vibration & Temperature Anomaly Detection

4g2g0g-2g-4g

Anomaly Spike (Bearing Risk)

AI Copilot

Spindle bearing on CNC Axis-M 01 is showing abnormal high-frequency vibration. Deviation matches historical failure profile. Confidence: 94%.

What is the estimated time to failure?

Remaining Useful Life (RUL) is approx 12 Hours. Recommend scheduling replacement on 3rd Shift to prevent unplanned downtime.

Component Failure Probability Matrix

Machine Component	Sensor Data Points	AI Anomaly Score	Remaining Useful Life (RUL)	Recommended Action
CNC M-01: Spindle Bearing	Vib: 4.2g \| Temp: 85°C	94% (Critical)	12 Hrs
Robot A: Joint 2 Servo Motor	Curr: 15A \| Temp: 60°C	65% (Warning)	5 Days
Conveyor: Main Drive Motor	Vib: 0.5g \| Temp: 40°C	12% (Normal)	45 Days+	No action needed

Area A - Machining Center

Area B - Automated Assembly

Area C - Packaging & Vision QC

Connected Edge Devices

Online

SGRID Core Edge

Central MQTT Broker (Cloud Sync)

CPU 24%Mem 1.2GBPing 12ms

Syncing

Siemens S7-1500

OPC-UA | Line A Master

Poll 100msTags 450Loss 0%

Idle

Cognex Vision Node

GigE Vision | QC Station 1

FPS 0Temp 42°CConn TCP

Timeout

Vibration Sensor M1

BLE / LoRaWAN | Spindle CNC

Bat 12%Last 15m ago

Financial Impact (IDR)

Total COPQ (Loss)

45.2

Juta

+5.2% Cost from Scrap

Downtime Opportunity Loss

112.5

Juta

High Unplanned Stops

Revenue Realized

1.45

Miliar

On Target (92%)

Environmental, Social, & Governance

Energy Consumption

45,210

kWh

-5.2% vs Last Month

Carbon Footprint

32.4

MT CO₂

Below Target Limit

Energy Cost

67.8

Juta

+1.2% Peak Tariff

OEEE (Efficiency)

0.85

kWh / Unit

Excellent Performance

Lost Revenue Analysis (By Root Cause)

100Jt50Jt0

Breakdown

Scrap Rate

Setup Time

Energy Consumption vs Production Output

10005000

MonWedFriSun

— Production (Units) - - Energy (kWh)

Report Parameters

Report Module

Plant Area

Start Date

End Date

SGRID Enterprise

Executive Summary Report

Date: 20 Feb 2026
Plant: Sinergi Main Plant

1. KPI Overview

Metric	Value	Target	Status
Plant OEE	86.5%	85.0%	Passed
Total Scrap	140 Units	200 Units	Passed
COPQ (IDR)	45.2 Juta	40.0 Juta	Failed

2. Top Downtime Drivers

Machine Breakdown (Area B): 4.2 Hours (32% of total loss)
Material Shortage (Area A): 2.1 Hours (16% of total loss)
Sensor Jam (Area C): 1.5 Hours (11% of total loss)

Prepared By
System Auto-Gen

Approved By
Plant Manager

Plant Setup

Master Data

Integrations

Administration

General Preferences

Plant / Factory Name

Timezone

Currency

Date Format

Auto-Refresh Dashboards

Realtime UI update via WebSockets

Shift Schedules Configuration

Define working hours. Required for accurate "Planned Time" calculation in OEE.

Shift Name	Start Time	End Time	Break (Mins)	Action
Shift 1 (Morning)
Shift 2 (Evening)
Shift 3 (Night)

Master Assets Configuration

Asset ID	Asset Name	Type	Area / Line	Design Speed	Status
MCH-001	Assembly Rob A	Robot Arm	Area A	120 U/m	Active
MCH-004	CNC Axis-M 01	Machining	Area B	5 U/m	Active
MCH-009	Wrapper Auto 1	Packaging	Area C	45 U/m	Active

Master Product (SKU)

SKU Code	Product Name	Mapped Asset	Ideal Cycle Time	Target Yield
PRD-ALPHA-V2	Widget Alpha V2	MCH-001	12.5 Sec	99%
PRD-GEAR-B	Gear Assembly B	MCH-004	45.0 Sec	98%
PRD-BOX-C	Packaging Box C	MCH-009	5.0 Sec	99.5%

Downtime Reason Codes

Loss Code	Category	Reason Description	OEE Impact Factor
PLN-01	Planned Stop	Setup / Tool Changeover	Availability
UNP-01	Unplanned Stop	Material Shortage	Availability
UNP-02	Unplanned Stop	Machine Breakdown	Availability
SPD-01	Micro-Stop	Sensor Jam / Blocked	Performance

IIoT Protocol Configuration

MQTT Broker URL

MQTT Port

Edge Username

Edge Password

Global Topic Prefix

Enable SSL / TLS Encryption

Require certificate for edge node connections

ERP Integration (API & Webhooks)

SAP / Oracle MES Sync

Automatically push Work Order completion and Quality Yield data to enterprise ERP.

ERP Webhook POST URL

Bearer Token / API Key

Sync Interval (Minutes)

User & Role Management

Name & Email	Role	Line Assignment	Last Login
Plant Manager admin@sinergi.com	Super Admin	All Areas	Just now
Budi Santoso budi@sinergi.com	Operator	Area A - Assembly	2 Hours ago
Arif QA arif@sinergi.com	QC Inspector	All Areas	1 Day ago

Alerts & Notification Gateway

WhatsApp API

Instance Key

Maintenance Group JID

SMTP Email

Host & Port

Auth Email

Trigger Thresholds

OEE Drops Below % Machine Down > Mins

Security & Data Retention

Raw Telemetry DB Retention

Session Timeout (Idle)

Require Two-Factor Auth (2FA)

Force all admin level users to authenticate via Google Authenticator or Email OTP before accessing settings.