Executive Manufacturing Dashboard

Live plant intelligence · Plant 01 · Shift B · updated 12s ago

Genau Extrusions logo
Production
11,542/ 12,800
90.2% achievement
OEE
78.4%
▲ 2.1 vs yesterday
Availability
87.3%
7/12 running
Quality Rate
96.8%
Rejection 3.2%
Downtime
92min
MTBF 148h · MTTR 22m
Plant Health
84/100
Energy 4820 kWh

Production — Target vs Actual (24h)

Hourly output across all lines

Live

OEE Composition (14d)

Availability · Performance · Quality

Downtime Pareto (24h)

Top loss reasons in minutes

Machine Status Map

All 12 machines · click on Digital Twin for details

7 running1 down
M101Status: running

Cold Forging

OEE72%
M102Status: running

Cold Forging

OEE79%
M103Status: running

Cold Forging

OEE86%
M201Status: running

CNC Turning

OEE93%
M202Status: idle

CNC Turning

OEE45%
M203Status: maintenance

Milling

OEE30%
M204Status: breakdown

Milling

OEE0%
M301Status: running

Heat Treatment

OEE77%
M302Status: running

Heat Treatment

OEE84%
M401Status: tool-change

Plating

OEE30%
M501Status: quality

Inspection

OEE30%
M601Status: running

Assembly

OEE83%

AI Recommendations

Correlated across PLC · Quality · SAP EAM

Bearing failure imminent on M102

critical

Vibration on M102 rose 22% over 72h. Bearing replacement is 18 days overdue in SAP PM. Similar pattern preceded 2 failures in the last 6 months.

Probability 87%→ Schedule preventive maintenance within 24h

Rejection correlated with hydraulic pressure on M202

warning

Diameter rejects on FRG-2048-A track a 6-bar pressure dip during Shift B. Root cause: accumulator pre-charge low.

Probability 74%→ Inspect accumulator pre-charge, retune PID

Energy optimization on Line 3

info

Induction hardening idle-time energy is 18% above baseline. Enabling standby mode between batches saves ~640 kWh/week.

Probability 92%→ Enable standby profile in recipe manager

Active Alarms

5 unacknowledged

10:42:11M102critical

Vibration exceeded critical threshold (7.8 mm/s)

OPEN
10:38:02M301warning

Coil temperature approaching upper limit (742°C)

OPEN
10:31:45M203critical

Spindle motor current spike detected

ACK
10:22:18M401warning

Zinc bath concentration below setpoint

OPEN
10:14:03M103info

Tool change reminder — 500 cycles remaining

ACK
09:58:29M202critical

Hydraulic pressure loss — safety interlock engaged

OPEN
Data sources: OPC-UA · Modbus TCP · MQTT · SAP EAM/PM · Vision AI · Energy meters