OEE Quality Intelligence — Defect Origin & COPQ

Meridian Plastics & Assemblies • 6 Product Families • Current Period: April 2024
Composite Quality Rate
94.6%
-1.2% vs target
COPQ (% Revenue)
4.8%
$284.4k • Target: 3.2%
First-Pass Yield
91.2%
+0.4% WoW
Rework Hrs/1k Units
18.4
+2.1 vs baseline
Escape Rate
1.8%
2 customer returns
Open CARs >30 Days
7
Closure rate: 68%

Defect Pareto by Cause Code (April 2024)

FPY by Product Family × Shift

Rework Labor Cost per Product Family

Tool Wear Defect Index Curve (Tool T-204)

Defect Density by Cavity (T-204)

Material Lot Defect Correlation (Top 12 Lots)

Lot ID Supplier Material Received Units Consumed Defect Rate Defect Delta Top Defect Status
LT-4421 Veltex Corp ABS-GF20 Apr 9 12,840 4.1% +3.2× Dim OOT Hold
LT-4409 PolySource Ltd PC-FR Apr 3 8,230 1.9% +1.5× Surface Defect Monitor
LT-4402 MatFlex Inc PP-Copo Apr 1 15,600 1.3% +0.1× Flash OK
LT-4415 Veltex Corp ABS-GF20 Apr 6 11,200 1.2% −0.1× Incomplete Fill OK
LT-4428 PolySource Ltd Nylon-6 Apr 12 9,840 1.5% +0.3× Weld Line OK
LT-4434 MatFlex Inc PP-Copo Apr 16 13,100 1.1% −0.2× Contamination OK
LT-4398 AlphaPoly Co PET-GF30 Mar 29 7,450 2.1% +1.7× Warpage Monitor
LT-4441 PolySource Ltd PC-FR Apr 19 10,600 1.0% −0.3× Flash OK

Quality-OEE Sensitivity

Corrective Action Aging

Critical Alerts

Lot LT-4421 Escape
Customer return detected. CAR-2024-041 opened.
Tool T-204 Cavities 7, 18
3.1× defect rate. Alignment inspection scheduled.
Night Shift FPY Below Target
Family A: 93.1% vs. 95.8% day shift. Review training.

Escape Rate by Inspection Stage (April Units)

Defect Heatmap by Day × Cause Code (April 1–28)

Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Dim OOT
18
22
84
96
28
14
8
Surface Defect
34
31
29
26
24
32
30
Incomplete Fill
16
19
72
58
21
17
12
Flash
14
18
22
16
15
19
17
Contamination
6
8
11
9
7
10
8
Warpage
12
15
13
14
16
18
15

Top Action Items

Immediate: Lot LT-4421 Root Cause
Complete supplier audit and material certification review by Apr 30.
Owner: Quality Mgr • CAR-2024-041
Tool T-204 Alignment Inspection
Cavities 7, 18 alignment check scheduled for Apr 27 shift changeover.
Owner: Maintenance • Due: Apr 27
Night Shift Training Review
Family A FPY gap 2.7 pts vs day. Schedule operator refresher training.
Owner: Production Lead • Due: May 3
Surface Defect Process Study
Second-highest defect code. Initiate DOE for mold temperature and cycle time.
Owner: Process Eng • Due: May 10
Escape Detection Rate Improvement
1.8% escape rate exceeds 1.0% target. Review in-line inspection coverage.
Owner: Quality Eng • Due: May 15