OEE Quality Loss Intelligence

MoldTech Precision | Real-time Cost of Poor Quality & Scrap Reduction Analytics

COPQ % of Revenue
4.8%
+0.6% vs target
Plant FPY
95.2%
vs 96.8% 8w ago
Defect Escape Rate
2.3%
Above 1.5% target
Quality OEE
93.1%
+1.2% MoM
Monthly COPQ
$214.8K
+$18K vs prior
SPC Signal Rate
6.8
signals/shift (tgt 2.0)

COPQ Dual-Axis Pareto by Defect Category

Quality OEE by Line & Shift (30d)

Inspection Yield Funnel by Station

Station
Yield
Pass %
In-Process 1
98.4%
In-Process 2
97.1%
In-Process 3
95.8%
Final Inspection
95.2%
Customer
92.9%
⚠ Defect escape: 2.3% detected at customer vs. 1.5% target — tighten Final Inspection

FPY Variance by SKU & Month (%)

M-6
M-5
M-4
M-3
M-2
M-1
SKU-C1
+0.4
+0.2
-0.8
-1.5
-2.4
-3.2
SKU-A2
+0.6
+0.5
+0.3
+0.1
-0.4
-0.6
SKU-B5
+0.2
+0.1
+0.3
-0.2
+0.1
+0.2
SKU-D3
+0.5
+0.4
+0.3
-0.3
-0.5
-1.1

SPC Out-of-Control Signals by Line

M-6
M-5
M-4
M-3
M-2
M-1
Line 1
1.8
2.1
1.9
2.0
2.4
2.3
Line 2
1.7
1.9
3.2
4.5
5.8
6.8
Line 3
2.0
1.8
2.1
2.6
2.8
3.2

SKU-Level COPQ Detail Table

SKU Product Family Line Std Cost FPY FPY Var Scrap Cost Rework Hrs Total COPQ
SKU-C1 Medical Housing Line 2 $94.00 91.8% -3.2% $76,420 184 $89,240
SKU-D3 Precision Valve Line 2 $68.50 93.9% -1.1% $38,620 96 $45,860
SKU-A2 Connector Assembly Line 1 $52.30 94.4% -0.6% $28,940 72 $34,120
SKU-B5 Medical Housing Line 1 $41.80 95.2% +0.2% $18,240 54 $22,680
SKU-E7 Sensor Mount Line 3 $34.20 96.1% +0.8% $12,860 38 $16,140

Rework Hrs/1K Units

Incoming Material NCR Rate

Quality-Adjusted Throughput

COPQ Category Trend (90d)

Top Defect Modes (Frequency)

Defect Mode × Root Cause Matrix

Defect Mode Frequency Root Cause Contributing Factor Cost Impact Action Status
Dimensional OOT 284 Coolant pH Drift Line 2 Day 22-24 mean shift $76,420 In Progress
Surface Finish 142 Tool Wear Extended tool life policy $38,940 Planned
Flash / Burr 96 Clamp Pressure Line 3 setup variation $24,160 Monitoring
Short Shot 68 Material Viscosity Resin lot variability $18,720 Resolved