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 · Cost1 active · 4 watching
Live feed
24m ago Downtime SentinelLINE-4 · Material starvation → resolved25m ago Downtime SentinelLINE-5 · Tool change → resolved58m ago Downtime SentinelLINE-1 · Sensor fault — replace required → resolved1h 27m ago Downtime SentinelLINE-2 · Material starvation → resolved20m ago Quality SentinelWO-83941 RAV4 Bumper Stamping Set flagged delayed20m ago Quality SentinelWO-83370 4Runner Skid Plate flagged delayed24m ago Downtime SentinelLINE-4 · Material starvation → resolved25m ago Downtime SentinelLINE-5 · Tool change → resolved58m ago Downtime SentinelLINE-1 · Sensor fault — replace required → resolved1h 27m ago Downtime SentinelLINE-2 · Material starvation → 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 ★$13.4K
Hold batch — Dimension out of tolerance on LINE-3$7.0K
Hold batch — Paint run / sag on LINE-2$6.4K
BIG BET$46.1K
Recover LINE-1 from changeover overran smed target$17.4K
Recover LINE-4 from material starvation$6.6K
Catch up overdue PM — ABB Robot 1$4.2K
Realign L1-FA cadence to demand curve$2.8K
+ 3 more
BIG BET—
no items
QUICK WIN$7.3K
Recover LINE-1 from material starvation$3.0K
Recover LINE-5 from sensor fault — replace required$2.2K
Reorder CER-WHL-100MM — 1d supply$2.2K
STANDARD—
no items
STANDARD—
no items
INCREMENTAL—
no items
STANDARD—
no items
DEPRIORITIZE—
no items
12 OPPORTUNITIES MAPPED$66.8K 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