MAIA · Compliance & Safety Command
Compliance
One pane of glass for OSHA, EPA, ISO and customer audit posture across the plant. Live cert horizon, permit traffic, Heinrich-pyramid trip-wires, and the next 30 days of forecasted breaches — with mitigations one click from the line floor.
Live · — MAIA monitoring 312 operators
187
Days since last LTI
+12d vs prior
1.84
OSHA TRIR (12-mo rolling)
Industry avg 3.10
0.62
LTIR (12-mo rolling)
−0.18 QoQ
94%
Audit readiness
ISO 9001 + IATF
2841
Active certifications
across 312 operators
47
Expiring · 30d
9 require external recert
23
Open audit findings
3 critical · 6 major
8
Overdue training
blocking 2 shifts
14
Permits active now
4 hot-work · 3 LOTO
47
Near-miss rate · 7d
Heinrich base
Forward-Look · 90 Days
Compliance horizon
Every cert expiry, audit window, training due-date, permit renewal and regulatory deadline plotted against today. Hover any chip for the full record.
Breach risk
Due soon
Scheduled
On track
Today
0d
+10d
+20d
+30d
+40d
+50d
+60d
+70d
+80d
+90d
Operator certifications
8 events
Audit windows
5 events
Training & drills
6 events
Permit renewals
5 events
Regulatory deadlines
6 events
Heinrich Triangle · 90d
Safety incident pyramid
The base is what predicts the apex. We track unsafe conditions and near-misses with the same rigor as recordables.
Fatality
Plant target: 0 always
0
0
Lost-time injury
Last 90d · L4-STMP press finger pinch
-1
1
Recordable
12-mo trailing 11
-2
3
First-aid
Mostly L3-WLD spatter burns
+1
12
Near-miss
Reporting rate up — culture signal
+6
49
Unsafe condition
Operator-led observations
+18
124
118 unsafe conditions reported · the wider this base, the safer the apex
Operator × Machine
Certification expiry — next out
Top 12 expiring credentials sorted by days-to-expire. One-click re-cert kicks off a calendar invite + training-system request.
| Operator | Cert | Issued | Expires | Days | Action |
|---|---|---|---|---|---|
Michael Johnson Line Operator · L1-FA | LOTO Authorization LOTO-29CFR1910.147 | May 9 | May 9 | 3d | |
Jose Garcia Material Handler · L2-FA | Powered Industrial Truck PIT-29CFR1910.178 | May 11 | May 11 | 5d | |
Christopher Miller CNC Machinist · L3-WLD | Overhead Crane Operator CRN-ASME-B30.2 | May 14 | May 14 | 8d | |
Miguel Martinez Line Operator · L4-STMP | Confined Space Entry CSE-29CFR1910.146 | May 17 | May 17 | 11d | |
Marcus Brown Quality Inspector · L5-PAINT | Hot Work Permit Issuer HW-NFPA-51B | May 20 | May 20 | 14d | |
Harpreet Singh Maintenance Technician · L6-CNC | MEWP Operator (Aerial) MEWP-ANSI-A92.24 | May 24 | May 24 | 18d | |
Anthony Davis Production Lead · L1-FA | FRA Structural Welding WLD-AWS-D1.1 | May 28 | May 28 | 22d | |
Rafael Lopez Line Operator · L2-FA | ISO 9001 Lead Auditor QMS-ISO-9001-LA | Jun 2 | Jun 2 | 27d | |
Tyler Wilson Material Handler · L3-WLD | First Aid / CPR / AED FA-ARC-2024 | Jun 8 | Jun 8 | 33d | |
Kevin Robinson Paint Line Operator · L4-STMP | Hazwoper 8-Hour Refresher HZW-29CFR1910.120 | Jun 16 | Jun 16 | 41d | |
Jaspreet Dhillon CNC Machinist · L5-PAINT | Pyrometer SAT (CQI-9) PYR-AIAG-CQI-9 | Jun 27 | Jun 27 | 52d | |
Darnell Jackson Line Operator · L6-CNC | Robot Safety (R15.06) RBT-ANSI-R15.06 | Jul 13 | Jul 13 | 68d |
Live · Plant Floor
Active permits & LOTO
Hot-work, confined-space, LOTO and at-height permits open right now across all six lines. Card border = permit status; countdown pulses when within 30 minutes of expiry.
2 Hot Work 3 LOTO 2 Confined Space
Hot Work
PWO-2400
LOCATIONL1-FA · Fanuc Weld 2
HOLDERDarnell Jackson
SIGNERSM. Torres · H. Perez
ISOLATIONSEnergy: pneumatic 80psi · Tag #114
Issued 6:41 PM → Exp 10:11 PM
0 min
Confined Space
PWO-2401
LOCATIONL2-FA · Stamping Press 1
HOLDERCarlos Rivera
SIGNERSA. Harris · J. Moore
ISOLATIONSAtmosphere monitor on · Rescue plan posted
Issued 6:16 PM → Exp 7:33 PM
0 min
LOTO
PWO-2402
LOCATIONL3-WLD · Conveyor B
HOLDERAmandeep Grewal
SIGNERSH. Perez · O. Ramirez
ISOLATIONSElectrical 480V isolated · Tag #117
Issued 5:51 PM → Exp 7:26 PM
0 min
Hot Work
PWO-2403
LOCATIONL4-STMP · Paint Booth Oven
HOLDERBrian Taylor
SIGNERSJ. Moore · D. Scott
ISOLATIONSWelding screens up · Fire watch posted
Issued 5:26 PM → Exp 8:41 PM
0 min
LOTO
PWO-2404
LOCATIONL5-PAINT · Robot Cell 1
HOLDERLuis Hernandez
SIGNERSO. Ramirez · R. Sanchez
ISOLATIONSPower · Panel L3-2 OFF · Padlock on E-stop
Issued 5:01 PM → Exp 11:11 PM
0 min
Working at Height
PWO-2405
LOCATIONL6-CNC · Catwalk South
HOLDERJordan White
SIGNERSD. Scott · M. Walker
ISOLATIONSFall arrest engaged · Anchor verified
Issued 4:36 PM → Exp 8:11 PM
0 min
Confined Space
PWO-2406
LOCATIONL1-FA · Pit · CNC 3
HOLDERManuel Torres
SIGNERSR. Sanchez · Z. Nguyen
ISOLATIONSO₂ 20.8% · LEL <3% · Continuous monitor
Issued 4:11 PM → Exp 7:46 PM
0 min
Energized Electrical
PWO-2407
LOCATIONL2-FA · Main Switchgear
HOLDERAndre Harris
SIGNERSM. Walker · A. Price
ISOLATIONSPhase rotation verified · PPE Cat 4 worn
Issued 3:46 PM → Exp 7:23 PM
0 min
LOTO
PWO-2408
LOCATIONL3-WLD · Press 2 ram
HOLDERHector Perez
SIGNERSZ. Nguyen · R. Castillo
ISOLATIONSHyd dump valve open · Stored energy bled
Issued 3:21 PM → Exp 9:01 PM
0 min
Findings Tracker
Audit findings — open queue
OSHA, EPA, customer-audit and certification-body findings, grouped by severity. Days-open trip-wires escalate to the EHS director at 30d.
| ID | Source | Description | Owner | Due | Days open | Status | |
|---|---|---|---|---|---|---|---|
F-2401 Critical | OSHA | Machine guarding gap on L4-STMP Press 2 — interlock bypass detected during inspection. | Ricardo Sanchez | May 10 | 8d | in progress | |
F-2402 Critical | OSHA | Hearing conservation program — annual audiogram completion at 81%, must reach 100%. | Malik Walker | May 17 | 14d | in progress | |
F-2403 Critical | Customer | Toyota TPS finding — non-conforming material containment process undocumented. | Zachary Nguyen | May 8 | 19d | verifying | |
F-2404 Major | ISO Body | ISO 14001 — stormwater outfall sample log gap during week of Apr 3. | Adrian Price | May 13 | 22d | in progress | |
F-2405 Major | ISO Body | AIAG CQI-9 — pyrometer SAT documentation missing for 2 of 6 thermocouples. | Robert Castillo | May 20 | 12d | open | |
F-2406 Major | EPA | EPA NPDES — TSS exceedance on Apr 18 outfall sample · root cause TBD. | Mark Singh | May 26 | 9d | open | |
F-2407 Major | Internal | Internal — LOTO procedure on L3-WLD missing energy-source verification step. | Cody Mitchell | May 12 | 17d | in progress | |
F-2408 Minor | Internal | Eye-wash station inspection log gap · Bay 4 (4 weeks). | Thomas Morales | May 9 | 5d | verifying | |
F-2409 Minor | OSHA | Overhead crane annual inspection paperwork from vendor delayed. | Joshua Wilson | May 14 | 11d | open | |
F-2410 Minor | Customer | Subaru of Indiana — ESD wrist-strap calibration logs sampled — 2 of 12 missing. | Walter Collins | May 21 | 7d | in progress | |
F-2411 Observation | Internal | Observation — chemical SDS binder Bay 3 last printed 2024-Q4. No compliance gap. | Logan Cooper | Jun 3 | 4d | open | |
F-2412 Observation | Internal | Observation — ergonomic mat condition on L1 station 7 worn (replace within 60 days). | Avery Griffin | Jun 13 | 3d | open |
Regulatory Posture
Framework heatmap
Eight active frameworks, one rating cell each. Last audit + next due window — click to drill into the underlying controls.
OSHA 29 CFR 1910
Federal
Compliant
LAST AUDIT
Feb 14
NEXT DUE
Aug 14
GAPS
0
EPA NPDES Permit
Federal
Minor gap
LAST AUDIT
Jan 22
NEXT DUE
Jul 22
GAPS
2
IATF 16949
Customer
Compliant
LAST AUDIT
Nov 8
NEXT DUE
Nov 8
GAPS
0
ISO 9001:2015
QMS
Compliant
LAST AUDIT
Dec 3
NEXT DUE
Dec 3
GAPS
0
ISO 14001:2015
EMS
Minor gap
LAST AUDIT
Mar 19
NEXT DUE
Sep 19
GAPS
1
ISO 45001:2018
OH&S
Compliant
LAST AUDIT
Apr 2
NEXT DUE
Oct 2
GAPS
0
AIAG CQI-9 (Heat)
Customer
Major gap
LAST AUDIT
Apr 19
NEXT DUE
May 22
GAPS
4
Customer-specific
Toyota TS
Minor gap
LAST AUDIT
Mar 28
NEXT DUE
Sep 28
GAPS
2
MAIA · 30-Day Forecast
Breach risk — top 5
Probabilistic projection from cert horizon × shift roster × audit calendar × incident pattern. Each row carries the recommended mitigation.
#1
LOTO certification gap on Line 3 by 2026-05-12
SIGNALCurrent LOTO holder (Harpreet Singh) rotates off shift; no qualified backup scheduled.
FIXSchedule expedited LOTO refresher for 2 swing-shift operators this week.
85%
by May 16
#2
OSHA 300A posting verification miss
SIGNALSite #4 has not confirmed annual injury log posting; deadline Feb 1 + 90d grace closing.
FIXAuto-dispatch posting kit + photographic confirmation request to site supervisor.
78%
by May 12
#3
AIAG CQI-9 surveillance · pyrometer SAT non-conformance
SIGNAL2 of 6 thermocouple SAT records gapped >12 mo. Customer surveillance window opens in 21 days.
FIXBook pyrometer Service Calibration Inc. for 2026-05-05 + add quarterly recurring task.
72%
by May 27
#4
Hot Work permit auto-issuance breach risk
SIGNALMAIA detected 4 hot-work permits in the last 7 days issued without fire-watch attestation log.
FIXTighten permit-template enforcement; require fire-watch sign-off before MAIA can issue.
61%
by May 20
#5
Contractor compliance — 3 vendors trending insurance lapse
SIGNALInsurance certificates for Magna Conveyors, Bosch Field Service, and Atlas Copco renewed late 2 of last 4 cycles.
FIXSend 30-day renewal reminders + prepare contingency vendor list.
54%
by Jun 3
Action Queue
Awaiting your review
MAIA has drafted the next moves. Each one carries its own evidence bundle — approve, edit, or reject in /actions.
Schedule re-cert · 3 operators expiring 14d
Crane + LOTO. Slots reserved at Toyota Training Center for 2026-05-08.
Issue LOTO refresh — incident pattern on L3-WLD
Heinrich pyramid trip-wire fired: 4 unsafe-condition reports in 7d.
Approve auto-drafted EPA NPDES quarterly return
MAIA prepared submission from MES + lab data; awaiting EHS sign-off.
Close out CQI-9 finding · pyrometer SAT calibration
Major finding from customer audit — recalibration scheduled tonight.
Revoke Hot Work permit — atmosphere drift on PWO-2418
LEL sensor trended >9% on Paint Booth — auto-suspend pending re-test.
Request OSHA 300A posting confirmation — all sites
Annual posting window opened. 1 of 4 sites confirmed.
Schedule contractor compliance review — 18 vendors
TPS contractor evaluation cycle due Q3. Templates ready in MAIA.