MAIA Intelligence — Intelligence. Precision. Action.

MAIA · Manufacturing intelligence

Performance

Operator-grade OEE accountability · skill leverage across 240 operators · 6 lines · 3 shifts. Every loss attributed to a person, a machine, or a process step.

INITIALIZING

Actions

Plant OEE

79.0%

Target 85% · 4/6 lines running

+0.8 pp

Top quartile OEE

87.7%

Mean of top 25% operators

+1.4 pp

Bottom quartile

73.7%

Gap to top: 14.0 pp

-0.6 pp

Skill coverage

31%

Avg cells operator-certified

+2 pp

Cross-train velocity

183

ops

Operators in active rotation

+12 wow

Coaching min · wk

6,221

Booked vs 6,400 capacity

Certs expiring

< 30d

Auto-routed to L&D

+3 vs last wk

Plant performance pyramid

Plant → Shift → Line → Operator

Click a row to drill

Plant

Toyota Indiana — Whole Plant

79.0%

Top ≥85%

On-target 75–85%

Watch 65–75%

Breach <65%

Plant target 85%

Operator leaderboard

Top 8 by composite score

OEE × Q × Att × Skill

01

MP

Michael Phillips

AL4-STMP

88.8

1.0

—

02

MJ

Michael Johnson

AL1-FA

88.7

0.2

—

03

TD

Thomas Dhillon

BL5-PAINT

87.9

0.3

+$242

04

SS

Shawn Smith

AL4-STMP

87.1

3.9

+$2k

05

TM

Thomas Morales

AL1-FA

87.0

2.2

+$2k

06

LG

Logan Gordon

BL5-PAINT

86.6

2.5

+$3k

07

CP

Christopher Perez

AL1-FA

86.5

2.4

+$3k

08

WT

Wayne Taylor

AL4-STMP

86.4

1.0

+$3k

OEE loss tree · last 24h

Where the lost units went — Availability × Performance × Quality

Availability Performance Quality

Availability loss

$60k

Breakdowns$11k

Planned$17k

Changeovers$10k

Material wait$22k

Performance loss

$413

Reduced speed$248

Minor stops$165

Quality loss

$24k

Defect scrap$19k

Rework$5k

Skill matrix

Operator certifications across cells

nonetraineecertifiedexperttrainer

Operator	Assembly	Weld	Paint	Stamp	CNC	Packaging	QA	Maintenance	Breadth
MP Michael Phillips A · L4-STMP	CER	CER	—	EXP	—	CER	EXP	—	63%
MJ Michael Johnson A · L1-FA	EXP	EXP	CER	—	CER	CER	—	—	63%
TD Thomas Dhillon B · L5-PAINT	EXP	EXP	CER	EXP	TRN	EXP	—	—	63%
LG Logan Gordon B · L5-PAINT	EXP	CER	EXP	—	CER	EXP	TRN	—	63%
HA Harpreet Alvarez B · L2-FA	CER	CER	CER	CER	—	—	TRN	CER	63%
BT Brian Taylor C · L3-WLD	—	EXP	—	CER	—	CER	EXP	CER	63%
JC Jason Campbell B · L5-PAINT	—	CER	EXP	EXP	CER	—	CER	TRN	63%
AM Adrian Martin C · L3-WLD	CER	EXP	—	—	EXP	—	CER	EXP	63%
CL Christopher Lopez B · L5-PAINT	CER	CER	EXP	—	CER	—	CER	—	63%
SS Shawn Smith A · L4-STMP	—	CER	CER	CER	CER	TRN	—	—	50%
TM Thomas Morales A · L1-FA	EXP	—	CER	TRN	EXP	—	—	CER	50%
JF Jaspreet Flores A · L1-FA	EXP	TRN	CER	—	EXP	—	—	EXP	50%
SJ Samuel Jones A · L4-STMP	CER	TRN	CER	EXP	EXP	TRN	—	—	50%
OJ Oscar Jackson A · L1-FA	CER	—	—	CER	CER	EXP	—	—	50%
DW Dylan Wilson C · L6-CNC	CER	CER	—	TRN	CER	—	CER	—	50%
SC Shawn Campbell A · L4-STMP	—	TRN	—	EXP	CER	CER	CER	—	50%

Coaching opportunities

Operators within 8 pts of next quartile

Sorted by $ uplift

HA

Harpreet Allen

C · Night · L3-WLD · current 70.8 → 75 target

coaching

+$32k

uplift

PO

Preston Ortiz

C · Night · L3-WLD · current 71.0 → 75 target

coaching

+$31k

uplift

WC

Walter Collins

C · Night · L3-WLD · current 71.5 → 75 target

coaching

+$31k

uplift

CG

Carlos Gomez

C · Night · L3-WLD · current 71.7 → 75 target

coaching

+$30k

uplift

MJ

Marvin James

C · Night · L6-CNC · current 71.8 → 75 target

coaching

+$30k

uplift

Cross-train priorities

Single-points-of-failure by cell

Risk weighted

Packaging

8 expert · 29 cert · 38 trn