DEMAND ENGINE · CUSTOMER PULL → PRODUCTION PULL
Demand Forecasting
Customer EDI orders, dealer pull, supplier lead time, and finished-goods buffer converged into one production plan for the next 14 days.
EDI · MES · SAP S/4 PP · live
Customer Demand · 7d
9.0k
units
Demand vs Capacity
+7.4k
over capacity
Open Backlog
7.9k
$750k
Confirmed Orders · 30d
41.1k
units committed
Forecast Accuracy
92.9%
MAPE 7.1% · 30d
Service Level · OTIF
94.2%
on-time-in-full · 90d
Dealer Days-of-Supply
18.4
avg · all SKUs
Inventory Turn Rate
8.7
turns / yr
STAGE PROGRESSION
Demand → Production funnel
Customer EDI orders flow through confirmation, scheduling, capacity allocation, and out the dock. Each stage shows attrition vs the upstream stage.
STAGE 01
EDI Demand · 14d
18.2k
intake
STAGE 02
Confirmed Orders
17.5k
96.0% conv
STAGE 03
Production Schedule
15.9k
91.0% conv
STAGE 04
Line Capacity Allocated
15.0k
94.0% conv
STAGE 05
Forecast Output
14.5k
97.0% conv
STAGE 06
Forecast Shipments
14.2k
98.0% conv
30-DAY PULL
Customer demand horizon
Top-6 customers, stacked. Dashed lines mark forecast confidence band; cyan vertical = today; dotted purple = annotated events.
14-DAY CAPACITY MAP
Capacity vs demand by line
Six lines × fourteen days. Cool = under-utilized, green = healthy, amber = tight, red = bottleneck. Hover any cell for line-day detail.
<60%
60-85%
85-100%
>100%
L1-FAFinal Assembly
L2-FAFinal Assembly
L3-WLDBody Weld
L4-STMPStamping
L5-PAINTPaint Shop
L6-CNCMachining
May 6
May 7
May 8
May 9
May 10
May 11
May 12
May 13
May 14
May 15
May 16
May 17
May 18
May 19
60
72
73
34
27
75
64
60
98
87
45
21
69
74
58
88
79
32
18
92
60
82
62
93
37
18
86
59
79
65
63
52
18
74
76
85
80
80
49
25
87
62
56
84
77
49
21
72
57
62
65
61
33
26
89
57
83
55
86
35
26
81
57
85
80
86
39
23
71
70
95
73
64
41
19
77
63
93
75
87
50
22
63
87
ACTIVE ORDER BOOK
Customer orders — top 12
Sorted by days-to-due. Click an action chip to send to MAIA.
| Customer | Order # | Product | Qty | Due | DTD | Status | Margin | |
|---|---|---|---|---|---|---|---|---|
| Honda Manufacturing | SO-93664 | BMW X5 Brake Caliper | 137 | May 6 | 0d | in queue | $16k | |
| Toyota North America | SO-90123 | Stellantis 1500 Bed Liner | 656 | May 7 | 1d | in production | $33k | |
| Linamar | SO-89768 | Stellantis 1500 Bed Liner | 655 | May 8 | 2d | in production | $63k | |
| BMW Group | SO-91053 | Tacoma Skid Plate | 368 | May 8 | 2d | in queue | $37k | |
| Martinrea | SO-92491 | RAV4 Bumper Set | 368 | May 8 | 2d | in queue | $18k | |
| BMW Group | SO-93839 | F-150 Frame Crossmember | 683 | May 9 | 3d | in production | $74k | |
| Martinrea | SO-92057 | BMW X5 Brake Caliper | 951 | May 11 | 5d | in production | $89k | |
| Linamar | SO-88041 | Honda Pilot Subframe | 398 | May 12 | 6d | in queue | $33k | |
| Honda Manufacturing | SO-87670 | Tesla Model Y Battery Tray | 1,302 | May 13 | 7d | in production | $160k | |
| Martinrea | SO-92990 | BMW X5 Brake Caliper | 898 | May 15 | 9d | in queue | $78k | |
| Magna International | SO-91276 | Mercedes GLE Knuckle | 321 | May 16 | 10d | in production | $30k | |
| Linamar | SO-90826 | Tesla Model Y Battery Tray | 1,135 | May 17 | 11d | ready to ship | $120k |
UPSTREAM EXPOSURE
Supplier lead-time risk
Top 8 input materials, current vs SLA.
BRG-6204-2RSBearing 6204-2RS sealed
Lear · OTIF 94% · lead 8d / SLA 5d · DOS 2d
68risk
RUBBER-EPDMEPDM rubber seal stock
Adient · OTIF 96% · lead 8d / SLA 5d · DOS 4d
46risk
STL-COIL-A572Steel coil A572 grade 50
Lear · OTIF 94% · lead 8d / SLA 5d · DOS 5d
46risk
FAS-M8-G88M8 fastener Grade 8.8
Lear · OTIF 94% · lead 11d / SLA 5d · DOS 5d
46risk
AL-SHT-6061Aluminum sheet 6061-T6
Bosch SA · OTIF 92% · lead 6d / SLA 5d · DOS 6d
46risk
CER-WHL-100MMCeramic grinding wheel 100mm
Denso · OTIF 85% · lead 7d / SLA 5d · DOS 6d
46risk
WIRE-MIG-070MIG welding wire 0.070"
Bosch SA · OTIF 92% · lead 4d / SLA 5d · DOS 14d
18risk
PAINT-CL-NX2Clearcoat NX2 Polyurethane
Aisin · OTIF 90% · lead 2d / SLA 5d · DOS 14d
18risk
FINISHED-GOODS BUFFER
Inventory buffer by product family
Current vs target stock, with burndown forecast at current consumption rate.
FAS-M8-G88
Fasteners — Grade 8.8
Current
1.7k
Target
1.9k
Cover
11.8d
BRG-6204-2RS
Bearings — Sealed
Current
874
Target
1.3k
Cover
10.5d
STL-PNL-A572
Stamped Panels — A572
Current
1.2k
Target
1.2k
Cover
5.5d
WLD-FRM-CRS
Welded Frames — Crossmember
Current
1.4k
Target
1.4k
Cover
6.7d
PNT-CL-NX2
Painted Bodies — NX2
Current
1.3k
Target
1.9k
Cover
5.3d
CNC-SHFT-G6
CNC Shafts — Grade 6
Current
1.0k
Target
937
Cover
5.2d
WHAT-IF
Scenario simulator
Click a preset to re-project the production plan against the current 14-day capacity envelope.
MAIA NEXT ACTIONS
Recommended production moves
Each recommendation is grounded in current EDI, capacity, and supplier signals. Tap to commit.
Move 800 units of L1 schedule to weekend OT
Clears Toyota Sept-30 due window; resolves 18-pt over-capacity on Wed
+$84k OT cost · +0.6 pt service level
Pre-position FAS-M8-G88 — Tue stockout-risk 0.74
Bosch SA lead time slipped 2d; lock 6,000-unit emergency buy at premium
Avoids L1 starvation · $4.2k premium cost
Defer Ford 1200-unit job — capacity gap, slot Oct-08
Ford Powertrain pre-cleared deferral; reuse slot for Tesla launch order
+$312k margin · 0 service level hit
Reroute BMW X5 caliper through L2 paint
L5 retrofit Tue-Wed; L2 has 22% open capacity, cycle-time delta < 4%
Holds OTIF · -$36k margin recovered
Confirm Stellantis 1500 bed liner — slot 16-19
Quote outstanding 9d; capacity confirmed, margin model green
+$148k pipeline · 4-day decision window