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Mean time between failures fell from 18 hours to 11 hours (breakdowns up 64% YoY); top 3 equipment families cause 78% of downtime hours

Reactive maintenance: 68% of maintenance hours (industry bench: 25%); PM schedule compliance dropped to 51% after maintenance manager departure 10 months ago

Average changeover time: 94 minutes vs 62-minute target; SMED analysis not conducted since 2021 — 8 of 22 tooling transfers involve manual alignment with no standardised procedure

Planned downtime as % of scheduled time: 18% (bench: 8%); changeover frequency increased 22% due to smaller batch sizes from demand mix shift

Average cycle time: 42 seconds vs 32-second standard (31% worse); tool wear not logged on 34% of production runs — no closed-loop cycle time monitoring

8 of 22 presses running at <75% rated speed; operators applying informal "caution speed" practice — no documented engineering justification in 6 cases

Minor stoppages (<10 min): 4.2 per shift (bench: 1.5); 73% linked to feed-system jams on granule lines installed in 2019 — no scheduled clearing protocol

Speed loss accounts for 38% of total OEE gap; performance rate: 79% vs 92% target — second-largest OEE loss category after availability

Overall first-pass yield: 86% (down from 93%); 3 of 18 product families account for 61% of scrap volume — all 3 use same legacy mould design from 2017

Scrap cost: $2.1M YTD vs $0.9M same period prior year (+133%); rework labour adds $0.4M — total quality cost equivalent to 4.8% of revenue

SPC control charts active on only 6 of 22 press lines; dimensional inspection: end-of-batch only vs in-process on high-scrap families — defect detection lag: 2.8 hours average

Customer complaint rate: 3.2 per 100 shipments (up from 1.1); ISO 9001 internal audit flagged 4 major NCRs on process control documentation in last cycle