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
9.1k
units
Demand vs Capacity
+7.5k
over capacity
Open Backlog
10.2k
$866k
Confirmed Orders · 30d
40.2k
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
9.7
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 8
May 9
May 10
May 11
May 12
May 13
May 14
May 15
May 16
May 17
May 18
May 19
May 20
May 21
78
34
25
64
84
67
62
65
48
25
68
91
59
74
83
33
20
81
88
64
91
63
48
20
91
85
80
82
65
40
26
76
87
78
77
64
49
27
70
68
94
67
65
43
20
83
69
62
59
65
33
25
53
81
78
60
80
43
26
87
73
105
55
80
40
22
60
90
89
68
72
31
22
59
78
65
67
65
52
23
81
77
67
79
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 | |
|---|---|---|---|---|---|---|---|---|
| Martinrea | SO-88583 | Tundra Hood Subassembly | 294 | May 8 | 0d | late risk | $25k | |
| Rivian Normal | SO-92576 | Tacoma Skid Plate | 404 | May 8 | 0d | late risk | $35k | |
| Mercedes-Benz US | SO-89508 | Tundra Hood Subassembly | 1,450 | May 11 | 3d | in queue | $162k | |
| Mercedes-Benz US | SO-86027 | Ford Lightning Pack Frame | 300 | May 11 | 3d | in production | $24k | |
| Ford Powertrain | SO-85556 | Camry Door Module | 1,269 | May 11 | 3d | in queue | $162k | |
| Linamar | SO-93900 | Ford Lightning Pack Frame | 1,208 | May 12 | 4d | in queue | $84k | |
| Martinrea | SO-91342 | Stellantis 1500 Bed Liner | 581 | May 16 | 8d | in queue | $23k | |
| Honda Manufacturing | SO-86689 | Ford Lightning Pack Frame | 1,349 | May 17 | 9d | in queue | $90k | |
| Martinrea | SO-88622 | Rivian R1T Motor Mount | 1,107 | May 17 | 9d | in queue | $91k | |
| Stellantis | SO-93214 | Sienna Side Panel-R | 635 | May 18 | 10d | in production | $72k | |
| Linamar | SO-93537 | Tesla Model Y Battery Tray | 895 | May 19 | 11d | in queue | $51k | |
| Honda Manufacturing | SO-91184 | Tesla Model Y Battery Tray | 694 | May 21 | 13d | in production | $49k |
UPSTREAM EXPOSURE
Supplier lead-time risk
Top 8 input materials, current vs SLA.
CER-WHL-100MMCeramic grinding wheel 100mm
Magna · OTIF 86% · lead 9d / SLA 5d · DOS 1d
68risk
PAINT-CL-NX2Clearcoat NX2 Polyurethane
BorgWarner · OTIF 89% · lead 7d / SLA 5d · DOS 3d
46risk
WIRE-MIG-070MIG welding wire 0.070"
Aisin · OTIF 90% · lead 8d / SLA 5d · DOS 5d
46risk
RUBBER-EPDMEPDM rubber seal stock
Adient · OTIF 96% · lead 8d / SLA 5d · DOS 5d
46risk
AL-SHT-6061Aluminum sheet 6061-T6
Bosch SA · OTIF 92% · lead 6d / SLA 5d · DOS 6d
46risk
STL-COIL-A572Steel coil A572 grade 50
BorgWarner · OTIF 89% · lead 7d / SLA 5d · DOS 8d
46risk
FAS-M8-G88M8 fastener Grade 8.8
Lear · OTIF 94% · lead 10d / SLA 5d · DOS 8d
46risk
BRG-6204-2RSBearing 6204-2RS sealed
Magna · OTIF 86% · lead 3d / 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
1.5k
Cover
8.1d
BRG-6204-2RS
Bearings — Sealed
Current
1.0k
Target
1.5k
Cover
11.1d
STL-PNL-A572
Stamped Panels — A572
Current
1.1k
Target
875
Cover
5.6d
WLD-FRM-CRS
Welded Frames — Crossmember
Current
1.6k
Target
1.5k
Cover
9.9d
PNT-CL-NX2
Painted Bodies — NX2
Current
1.0k
Target
1.6k
Cover
9.1d
CNC-SHFT-G6
CNC Shafts — Grade 6
Current
817
Target
1.6k
Cover
6.5d
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