RULES · BUSINESS RULE ENGINE
Rules engine · the law of the plant floor
Production, quality, maintenance, safety, cost, compliance. Every rule has a trigger, an action, an autonomy ceiling, and an audit trail. Hard-stops are immutable below the safety officer.
RULES
22
across 6 domains
LIVE
21
enforcing in production
FIRINGS · 7d
182
across all rules
BLOCKING
2
hard-stop on violation
Domain
Autonomy
| Rule | Domain | Trigger (when) | Action (then) | Autonomy | Last fired | 7d | Status | |
|---|---|---|---|---|---|---|---|---|
OEE drop · root-cause flag r-prod-1 · M. Gutierrez | Production | If line OEE drops ≥ 8 percentage points within any 2-hour window | Open RCA ticket, assign to cell engineer, surface in cockpit, ping Slack | Autonomous · bounded | 47 min ago · L2-FA | 18 | live | |
Schedule attainment <85% at hour 6 r-prod-2 · Plant Ops | Production | If schedule attainment < 85% by hour 6 of shift | Propose end-of-shift reschedule, request operator authorization to publish | Assisted | yesterday · L4-STMP | 4 | live | |
WIP buffer empty for 5 min r-prod-3 · Plant Ops | Production | If station inbound buffer = 0 for ≥ 5 min | Notify upstream cell + dispatch material handler | Autonomous · bounded | 2 hr ago · L1-FA st-7 | 31 | live | |
Cycle time > 1.15× target r-prod-4 · M. Gutierrez | Production | If actual cycle time exceeds 115% of target for 3 consecutive parts | Flag suspected operator hesitation or fixture wear; suggest root-cause | Advisory | 33 min ago · L3-WLD | 62 | live | |
Defect bin > 5 in 1 hr r-qa-1 · L. O'Brien | Quality | If defect bin count > 5 within any 1-hour rolling window | Halt routing to that station, alert quality engineer, open SPC review | Autonomous · bounded | 3 hr ago · L5-PAINT (PAINT_RUN) | 11 | live | |
FPY < 95% on weld cell r-qa-2 · L. O'Brien | Quality | If first-pass-yield drops below 95% on any weld cell in 30-min window | Pause routing, schedule torch inspection, propose program reload | Assisted | yesterday | 3 | live | |
CV defect drift > 0.05 vs 7d r-qa-3 · L. O'Brien | Quality | If Quality-Vision-CV defect-rate baseline drifts > 0.05 vs 7-day average | Re-train CV head on last 48h images, hold deployment for review | Advisory | 5 days ago | 1 | live | |
Customer-spec violation r-qa-4 · L. O'Brien | Quality | If outbound part fails customer-spec acceptance test (any criterion) | Quarantine bin, open NCR, hold downstream WO, notify customer-quality liaison | Autonomous · bounded | 2 days ago | 2 | live | |
RUL < 7 days · auto-PM r-mnt-1 · T. Yamamoto | Maintenance | If Maintenance-RUL predicts < 7 days remaining useful life on any rotating asset | Schedule predictive PM in next changeover window, reserve part from stock | Autonomous · bounded | yesterday · L3-WLD-m1 | 6 | live | |
Vibration RMS > 4.5 mm/s r-mnt-2 · T. Yamamoto | Maintenance | If vibration RMS exceeds 4.5 mm/s on any spindle for ≥ 15 min sustained | Flag for inspection, propose downgrade to 80% load until cleared | Assisted | today 09:42 · L6-CNC-m4 | 4 | live | |
PM overdue > 48 hours r-mnt-3 · T. Yamamoto | Maintenance | If any preventive maintenance task is > 48 h past due date | Escalate to maintenance manager, block upstream WO scheduling on that asset | Autonomous · bounded | 3 days ago | 0 | live | |
Tech response > 12 min SLA r-mnt-4 · Plant Ops | Maintenance | If technician response to critical alert exceeds 12-min SLA | Auto-page next-on-call, log SLA breach for monthly review | Advisory | today 11:08 | 7 | live | |
LOTO permit overdue → block WO r-sfy-1 · EHS | Safety | If any LOTO permit is overdue OR not issued for an active maintenance task | BLOCK work-order start. No override below safety-officer auth. | Autonomous · full | 8 days ago | 0 | live | |
Operator cert expires in 7d r-sfy-2 · EHS | Safety | If operator certification expires within 7 days for actively-scheduled role | Auto-schedule recert in next slot, notify operator + supervisor | Autonomous · bounded | today 06:30 | 14 | live | |
Near-miss in last 24h on cell r-sfy-3 · EHS | Safety | If ≥ 1 near-miss reported in last 24h on a cell with active production | Pause cell for 5-min stand-down, deliver SBAR brief, log acknowledgment | Advisory | 4 days ago | 1 | live | |
Fatigue score > 80 · operator pull r-sfy-4 · EHS | Safety | If Operator-Fatigue-Predictor score > 80 for any operator on duty | Propose 15-min break + rotation, notify shift lead for approval | Assisted | today 10:14 | 9 | live | |
Material days-of-supply < 2 r-cost-1 · Procurement | Cost | If material days-of-supply (DOS) drops below 2 and supplier OTIF < 0.85 | Auto-expedite PO with carrier upgrade up to $5,000 freight cap | Autonomous · bounded | today 04:51 · BRG-6204-2RS | 5 | live | |
Scrap cost > $1,500/shift r-cost-2 · Finance | Cost | If cumulative scrap cost > $1,500 on any single shift | Flag in cost dashboard, draft RCA, brief plant manager in next briefing | Advisory | yesterday | 2 | live | |
Energy spike > 1.2× forecast r-cost-3 · Facilities | Cost | If 15-min plant kWh > 1.2× Energy-Forecaster prediction during TOU peak window | Auto-shed non-critical HVAC load, defer paint-bake to off-peak | Autonomous · bounded | 2 days ago | 1 | live | |
IATF 16949 · audit-log gap r-cmp-1 · Compliance | Compliance | If audit-log gap > 30 sec detected on any production line in last 24 h | Open compliance ticket, lock evidence, notify auditor on call | Advisory | 1 wk ago | 0 | live | |
Operator without acknowledged SOP r-cmp-2 · Compliance | Compliance | If operator scheduled to station without acknowledged current SOP version | Block WO start, push SOP to operator tablet for signature | Autonomous · bounded | 3 days ago | 1 | live | |
Supplier change → re-qualify r-cmp-3 · Compliance | Compliance | If supplier of any IATF-tracked component changes within 90-day window | Trigger re-qualification workflow, hold incoming inspection at L1 (100%) | Advisory | — | 0 | draft |