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PLANTPILOT AI
CONTINUOUS IMPROVEMENT PLATFORM
DEMO 06 OF 08 · LIVE SYSTEM CONNECTORS & ALERT ENGINE
See how PlantPilot AI connects to ETQ Reliance, SAP S/4HANA, and SCADA systems — pulling live quality and production data, injecting it into the CI Agent's context, and firing threshold alerts automatically.
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PLANTPILOT AI
CONTINUOUS IMPROVEMENT PLATFORM
Facility:Apex Automotive Stamping LLCIATF 16949
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Claude AI Live
Operations
Systems 9
Alert Rules
CI Tools
Data Import
DMAIC Projects
Intelligence
CI Agent

Systems & Integration

Apex Automotive Stamping LLC · Live connectors: ETQ Reliance, SAP S/4HANA, SCADA · Credentials encrypted AES-256

✅
ETQ Reliance
Quality Management · IATF 16949
Connected · Last pull 2h ago
CAPAs, Corrective Actions, Nonconformances, Audit Findings — live records pulled via REST API.
🏭
SAP S/4HANA
ERP · OData API
Connected · Last pull 2h ago
Inspection Lots, Quality Notifications, Production Orders, Material Movements — pulled via OData v2.
📡
SCADA / PLC
Production · Push Webhook
Active · Receiving push data
OEE metrics, alarms, production counts — SCADA pushes JSON to PlantPilot's webhook endpoint.
🔬
Intelex
Quality · EHS
Not configured
Quality and EHS management. API connector available — add credentials to enable live pull.
⚡
MachineMetrics
Production · OEE
Not configured
Real-time OEE, downtime, cycle time. API connector available.
📦
Minitab / Excel
Analytics · CSV Import
CSV import active
Import historical data exports from any system via CSV — AI maps columns automatically.
PLANTPILOT AI · LIVE DATA ACTIVE
PlantPilot AI has ingested live data from 3 connected systems. ETQ: 8 open CARs (2 high priority), 14 open CAPAs (3 overdue). SAP: 12 inspection lots (4 with nonconforming units), 4 quality notifications. SCADA: avg OEE 71.4% — below 75% alert threshold. All data is available to the CI Agent and evaluated daily by the alert engine.

Systems & Integration

Configuring ETQ Reliance — credentials encrypted before storage

✅
ETQ Reliance
Quality Management
Connected
CAPAs, CARs, NCRs, Audit Findings
🏭
SAP S/4HANA
ERP · OData API
📡
SCADA / PLC
Push Webhook
🔌
Configure ETQ Reliance
Credentials are encrypted with AES-256 before storage
🔐

Sensitive fields (API keys, passwords) are encrypted with AES-256-GCM before being stored. They are never logged, never returned to the browser, and only decrypted server-side when PlantPilot pulls data.

ETQ BASE URL
https://apex.etq.com
API KEY ● ENCRYPTED
••••••••••••••••••••••

Live Data Pull Results

ETQ Reliance + SAP S/4HANA · 4 datasets each · Pulled in parallel via server-side API calls

✅ ETQ Reliance 54 records pulled Pulled 08:14 AM · 3.2s
Corrective Actions
8
Open CARs — 2 high priority, oldest 47 days open
CAPAs
14
Open CAPAs — 3 past due date
Nonconformances
11
Open NCRs across 3 suppliers
Audit Findings
6
Open findings — 2 major (IATF 7.1.4, 9.1.1)
🏭 SAP S/4HANA 86 records pulled Pulled 08:14 AM · 4.8s
Inspection Lots
12
Open lots — 4 with nonconforming units
Quality Notifications
4
Open Q-notifs — 1 high priority (Ford PPM)
Production Orders
31
Released orders across 2 plants
Material Movements
39
Last 7 days — 6 scrap postings (type 551)

SCADA Webhook — Push Data Receiver

SCADA systems push JSON directly to PlantPilot · No polling · Auto-detects data type · Validated by webhook secret

⚙ Setup in 3 steps
1

Generate a webhook secret

Enter any strong random string in the SCADA Configure modal. PlantPilot stores it and uses it to validate every incoming push.

2

Copy the endpoint URL

PlantPilot shows your webhook URL in the Configure modal. Copy it into your SCADA system's outbound HTTP settings.

https://plantpilotai.com/api/connectors/webhook
3

SCADA pushes data automatically

Send JSON with header X-Webhook-Secret: your-secret. PlantPilot auto-detects OEE metrics, alarms, production counts, or process parameters from the payload shape.

📡 Live Incoming Pushes — Ignition SCADA
oee_metrics
Line 1 OEE: 78.4% · Avail: 91% · Perf: 88% · Qual: 97%
08:00:14
oee_metrics
Line 2 OEE: 63.1% · Avail: 74% · Perf: 86% · Qual: 99%
08:00:14
machine_alarms
Line 2 Press 6 — Overload fault · severity: critical
07:53:02
production_quality
Shift 1 total: 2,847 good · 91 reject · rate 3.1%
07:30:00
oee_metrics
Line 3 OEE: 88.2% · All KPIs green
06:00:09
AUTO-DETECTED · STORED · AGENT CONTEXT UPDATED
5 pushes received. Avg OEE across 3 lines: 76.6%. Line 2 critical alarm flagged. All snapshots injected into CI Agent context automatically.

Alert Rules

Set thresholds on live system data — PlantPilot evaluates daily and emails your team when a limit is crossed

Overdue CAPAs
Trigger when count > 0
✉ quality@apex-stamping.com
High-Priority Open CARs
Trigger when count > 3
✉ quality@apex-stamping.com
OEE Below Threshold
Trigger when avg OEE < 75%
✉ production@apex-stamping.com
Open Major Audit Findings
Trigger when count > 0
✉ quality@apex-stamping.com
Scrap Posting Spike
Trigger when SAP scrap postings > 5/week
✉ production@apex-stamping.com
Nonconforming Inspection Lots
Trigger when open lots with NCRs > 3
✉ quality@apex-stamping.com
Today's Alert Events
🚨
Overdue CAPAs: 3 open CAPAs past due date — exceeds threshold of 0.
Triggered 06:01 AM · ETQ Reliance data · 24h debounce active
✉ Email sent to quality@apex-stamping.com
⚠️
OEE Below Threshold: avg OEE 71.4% — below the 75% threshold.
Triggered 06:01 AM · SCADA data · 24h debounce active
✉ Email sent to production@apex-stamping.com

CI Agent — Live System Context

Every conversation starts with live ETQ, SAP, and SCADA data already injected into the agent's prompt

LIVE DATA INJECTED INTO AGENT PROMPT
ETQ / CAPAs
14 open CAPAs — 3 past due date.
2h ago
ETQ / CARs
8 open corrective actions (2 high priority).
2h ago
ETQ / NCRs
11 open nonconformances across 3 suppliers.
2h ago
ETQ / Audits
6 open audit findings — 2 major (IATF 7.1.4, 9.1.1).
2h ago
SAP / Lots
12 open inspection lots — 4 with nonconforming units.
2h ago
SAP / Scrap
39 material movements — 6 scrap postings (type 551).
2h ago
SCADA / OEE
6 OEE readings — avg OEE 71.4%.
8m ago
SCADA / Alarms
2 alarm events — includes critical alarm on Line 2.
15m ago
Context active · ETQ Reliance · SAP S/4HANA · SCADA · IATF 16949 · Apex Automotive Stamping
MW
What are our biggest quality risks right now, and what should we prioritise today?
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PLANTPILOT AI · LIVE DATA RESPONSE
Based on live data pulled this morning: (1) 3 overdue CAPAs — these are IATF 16949 compliance risks and must be closed or escalated today with documented justification. (2) 2 major audit findings on IATF clauses 7.1.4 and 9.1.1 — open major findings create customer audit exposure. (3) OEE at 71.4% — the SCADA data shows Line 2 availability at 74%, with a critical press fault at 07:53. I'd recommend starting with the overdue CAPAs. Want me to generate an overdue CAPA summary report for your quality review?
3 Live ConnectorsETQ Reliance, SAP S/4HANA, and SCADA are fully wired. Credentials are encrypted AES-256 and stored server-side — never exposed to the browser.
Pull vs PushETQ and SAP use pull — PlantPilot reaches out via API on demand. SCADA uses push — your SCADA system sends data to PlantPilot's webhook endpoint continuously.
AES-256-GCM Credential VaultSensitive fields are encrypted before hitting the database. The encryption key lives only in Vercel's server environment — never in code or client responses.
54 ETQ + 86 SAP RecordsFour datasets per system — pulled in parallel, normalized, and stored as live snapshots. Each pull takes 3–5 seconds on the server.
Push Webhook — Zero PollingYour SCADA system pushes JSON to the endpoint with a secret header. PlantPilot auto-detects the data type from the payload keys.
6 Alert Rules · Daily EvaluationAlert engine runs daily alongside the shift report cron. 24-hour debounce prevents email spam. Email sent via Resend when threshold is crossed.
Live Context → Better AnswersThe CI Agent knows Apex has 3 overdue CAPAs and an OEE of 71.4% before the conversation starts — no need to paste numbers or describe the situation manually.
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