Operations · Manufacturing · Cost Intelligence
Where every dollar goes, how much we claw back.
Labour spend MTD $1.41M · $157K recovered YTD (38% of standing recoverable). OT at 11.9% vs peer 13.2% · Agency at 10.5% vs peer 3.1%.
MAIA agents · Cost2 active · 4 watching
Live feed
35m ago Production WatcherL3-WLD stopped → routing operators to next cell58m ago Downtime SentinelLINE-1 · Quality hold — out-of-spec part → resolved1h 7m ago Downtime SentinelLINE-1 · Tool change → resolved4m ago Downtime SentinelLINE-5 · Material starvation → resolved1h 28m ago Downtime SentinelLINE-5 · Bearing failure on conveyor B → resolved20m ago Quality SentinelWO-83941 RAV4 Bumper Stamping Set flagged delayed20m ago Quality SentinelWO-83370 4Runner Skid Plate flagged delayed35m ago Production WatcherL3-WLD stopped → routing operators to next cell58m ago Downtime SentinelLINE-1 · Quality hold — out-of-spec part → resolved1h 7m ago Downtime SentinelLINE-1 · Tool change → resolved4m ago Downtime SentinelLINE-5 · Material starvation → resolved1h 28m ago Downtime SentinelLINE-5 · Bearing failure on conveyor B → resolved20m ago Quality SentinelWO-83941 RAV4 Bumper Stamping Set flagged delayed20m ago Quality SentinelWO-83370 4Runner Skid Plate flagged delayed
Where every dollar goes · payroll → bucket → recoverableMTD · $1.41M
Read this: ribbon thickness = share of payroll. Recoverable share is what MAIA agents could claw back over the next quarter through opportunities below.
Recovery trajectory · YTD + 4-month forecast ACTUAL FORECAST
Recovery lanes · YTD attribution
Agency avoidance$56.4K$19.9K/mo
OT rebalance$38.2K$9.5K/mo
Absence reduction$22.8K$4.8K/mo
Schedule efficiency$24.0K$3.9K/mo
Cross-training$15.4K$3.4K/mo
TOTAL YTD$156.8K
Savings matrix · effort × impact · top-left = quick wins
$3K+
$1-3K
<$1K
LOW EFFORT
MED EFFORT
HIGH EFFORT
QUICK WIN ★$14.9K
Recover LINE-3 from bearing failure on conveyor b$6.9K
Hold batch — Missing fastener on LINE-6$3.6K
Hold batch — Cosmetic scratch on LINE-1$4.5K
BIG BET$32.1K
Recover LINE-6 from material starvation$10.0K
Catch up overdue PM — ABB Robot 1$4.2K
Realign L2-FA cadence to demand curve$2.8K
Realign L3-WLD cadence to demand curve$2.8K
+ 2 more
BIG BET—
no items
QUICK WIN$5.2K
Recover LINE-5 from compressed air pressure low$3.0K
Reorder BRG-6204-2RS — 2d supply$2.2K
STANDARD—
no items
STANDARD—
no items
INCREMENTAL—
no items
STANDARD—
no items
DEPRIORITIZE—
no items
11 OPPORTUNITIES MAPPED$52.2K TOTAL
Peer benchmark · automotive manufacturers · n=127
Overtime % of payroll
11.9%vs 13.2% peer p50
Agency % of shifts
2.6%vs 3.1% peer p50
Absenteeism rate
5.8%vs 5.5% peer p50
Cost per productive hour
$34.20vs $31.50 peer p50
Incentive % of payroll
4.6%vs 5.4% peer p50
Voluntary turnover (12m)
14.2%vs 16.8% peer p50
Open-shift fill time
17mvs 34m peer p50
Cost per unit produced
$4.12vs $4.48 peer p50
Opportunity ledger · click to expand · approve to dispatch