Systems & Integration
Apex Automotive Stamping LLC · 9 systems catalogued · PlantPilot AI trained on all system context
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SAP S/4HANA
ERP · Production Management
Migration gap — tooling PM records incomplete
Production orders, BOM, purchasing, PM work orders. March go-live incomplete — tooling records not migrated.
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ETQ Reliance
QMS · IATF 16949
Active — 47 SOPs, PPAP tracking
Document control, CAPA management, PPAP, customer complaints, audit management.
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Minitab Statistical
Data Analysis · Six Sigma
Active — used in Line 2 DMAIC regression
Statistical analysis, Gauge R&R, regression, SPC charting, hypothesis testing.
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Allen-Bradley PLC
PLC Control · Line Automation
Lines 1–3 — 14 presses monitored
Press control, tonnage monitoring, stroke counter, fault codes. Lines 1–3 fully integrated.
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Vorne OEE Dashboard
OEE · Real-Time Monitoring
Live — OEE 74–92% by dept
Real-time OEE, downtime categorization, production count, shift performance tracking.
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ZEISS CMM (Calypso)
Dimensional Measurement
Active — Ford PPAP measurement
CMM measurement programs, dimensional reports, first article inspection, Cpk tracking.
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Oracle WMS
Warehouse · Shipping
Active — Ford EDI connected
Inventory management, shipping labels, EDI 856 ASN to Ford Wayne Assembly, finished goods tracking.
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Ignition SCADA
SCADA · Environmental
Active — Line 2 temp data in DMAIC
Temperature, humidity, air pressure monitoring. Line 2 thermal data used in scrap regression analysis.
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eMaint CMMS
Maintenance · PM Tracking
Legacy — being replaced by SAP PM module
Preventive maintenance scheduling, work orders, tooling hit counters. Being migrated to SAP.
PLANTPILOT AI · SYSTEMS CONTEXT ACTIVE
PlantPilot AI is trained on all 9 Apex systems. When you ask about production issues, it cross-references SAP work orders, Vorne OEE data, PLC fault codes, and ZEISS CMM reports to give answers grounded in your actual system data. The SAP migration gap (eMaint → SAP PM) is flagged as the root cause of the Line 2 PM miss — active in DMAIC project tracking.
Data Import
Import CSV, Excel, or paste data from any system — PlantPilot AI maps columns and loads data into your CI projects
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Drop your file here
CSV · Excel · TSV · Paste supported
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line2_scrap_30day.csv
14.2 KB · 247 rows · Loaded
✓ File parsed — 247 rows · 8 columns
PLANTPILOT AI · IMPORT ANALYSIS
247 scrap records imported from Line 2 (May 1 – May 31). Station 4 accounts for 71% of all defects. Peak scrap events correlate with end-of-shift changeovers (tool not re-set). Cpk from this dataset = 0.83 — confirms incapable process. Data has been linked to the Line 2 DMAIC Measure phase.
line2_scrap_30day.csv — Preview (10 of 247 rows)
Mapped to DMAIC Measure
| Date | Shift | Station | Part PN | Defect Type | Qty Good | Qty Scrap | Scrap % |
|---|---|---|---|---|---|---|---|
| 05/01 | 1st | Stn 4 | AP-2247 | Tear-out | 312 | 18 | 5.5% |
| 05/01 | 2nd | Stn 2 | AP-2247 | Burring | 298 | 7 | 2.3% |
| 05/02 | 1st | Stn 4 | AP-2247 | Tear-out | 305 | 21 | 6.4% |
| 05/02 | 2nd | Stn 7 | AP-1834 | Dent | 410 | 2 | 0.5% |
| 05/03 | 1st | Stn 4 | AP-2247 | Tear-out | 288 | 19 | 6.2% |
| 05/03 | 2nd | Stn 4 | AP-2247 | Tear-out | 302 | 9 | 2.9% |
| 05/04 | 1st | Stn 2 | AP-2247 | Burring | 318 | 5 | 1.5% |
| 05/05 | 1st | Stn 4 | AP-2247 | Tear-out | 295 | 24 | 7.5% |
| 05/05 | 3rd | Stn 9 | AP-1834 | Scratch | 401 | 1 | 0.2% |
| 05/06 | 1st | Stn 4 | AP-2247 | Tear-out | 309 | 16 | 4.9% |