Production data review — synthetic demo plant
Injection moulding, 4 machines, 8 products, 2026-08-03 to 2026-08-30. Three exports as the plant keeps them; every number below traces to a check or a formula on this page.
Summary
Reported good output (spreadsheet)
2,819,124
after checks 2,920,686 · ERP confirmed 2,949,353 · trusted 2,863,539
Scrap rate (pieces)
4.9%
top defects: Flash 33%, Short shot 33%
Downtime per shift-hour
3.1 min
largest class: Changeover 3,905 min of 8,230
1. Data received
| File | Owner | Rows | Period | Notes |
|---|---|---|---|---|
| shift_log.csv | Operators (spreadsheet) | 334 | 2026-08-03 – 2026-08-30 | date dd/mm/yyyy; product as code or name; downtime free text |
| erp_scrap.csv | ERP quality module | 682 | 2026-08-03 – 2026-08-30 | scrap in kg; defect codes |
| erp_output.csv | ERP production module | 112 | 2026-08-03 – 2026-08-30 | confirmed good quantity per work order |
| products.csv, machines.csv, shift_calendar.csv | Client masters | 8 | — | cavities, cycle time, part weight and its last update |
Findings
Each check runs in this order on the raw files. Counts are rows unless stated.
| Check | Count | Examples | What was done |
|---|---|---|---|
| parse_dates[shift_log] | 119 | 03/08/2026; 03/08/2026; 03/08/2026 | shift_log: format detected as dmy. 119 rows are ambiguous on their own (day and month both <= 12) and were resolved with the file-level format. |
| parse_dates[erp_scrap] | 0 | — | erp_scrap: format detected as iso. 0 rows are ambiguous on their own (day and month both <= 12) and were resolved with the file-level format. |
| map_products | 106 | — | 106 rows named the product instead of the part number; mapped through the product master. 0 rows could not be mapped. |
| dedupe | 4 | 2026-08-07 / A / IM-02 / P-1001; 2026-08-19 / C / IM-01 / P-1008; 2026-08-20 / B / IM-01 / P-1008 | Exact duplicate shift rows dropped; first occurrence kept. |
| coverage | 6 | 2026-08-08 / C / IM-03; 2026-08-09 / C / IM-04; 2026-08-15 / C / IM-04 | Planned shifts with no spreadsheet row. Output for these shifts exists only in ERP. |
| unit_convert | 2 | P-1003; P-1006 | ERP scrap is recorded in kg; converted to pieces with the product weight master. Listed products have a master weight older than 12 months, so their piece counts are approximate. |
| plausibility | 21 | 2026-08-10 A IM-02 ratio 0.12; 2026-08-10 B IM-02 ratio 0.14; 2026-08-10 C IM-02 ratio 0.14 | Reported pieces vs theoretical (run minutes x 60 / cycle x cavities). Rows below 0.5 look like shot counts, not pieces; corrected by the cavity count and marked as estimates. |
| normalize_downtime | 13 | cleaning; cleaning; cleaning | Free-text downtime reasons mapped to five classes by keyword; listed texts fell into 'other'. |
| cross_source | 17 | WO-260018 +3325; WO-260023 -2998; WO-260028 -3425 | Work orders where spreadsheet and ERP output differ before correction; the reason label says which earlier check explains the gap. |
2. Scrap
Scrap rate = scrap pieces / (good pieces + scrap pieces), spreadsheet rows after checks. Pareto uses ERP defect codes with kg converted to pieces.
Scrap rate by machine and product, highest first.
Defect Pareto, pieces per defect code with cumulative share.
Table: scrap by machine and product
| Machine | Product | Good | Scrap | Rate |
|---|---|---|---|---|
| IM-01 | P-1006 Clip | 1,170,768 | 77,904 | 6.2% |
| IM-01 | P-1003 Cap 20mm | 427,535 | 23,729 | 5.3% |
| IM-01 | P-1008 Spacer | 288,117 | 12,587 | 4.2% |
| IM-02 | P-1004 Cap 28mm | 412,517 | 17,270 | 4.0% |
| IM-04 | P-1007 Lid | 89,845 | 3,371 | 3.6% |
| IM-03 | P-1002 Housing B | 121,758 | 4,542 | 3.6% |
| IM-04 | P-1002 Housing B | 89,101 | 3,067 | 3.3% |
| IM-02 | P-1007 Lid | 108,883 | 3,546 | 3.2% |
| IM-02 | P-1001 Housing A | 77,681 | 2,340 | 2.9% |
| IM-04 | P-1001 Housing A | 91,633 | 2,559 | 2.7% |
| IM-03 | P-1005 Bracket | 42,848 | 982 | 2.2% |
Table: defect Pareto
| Code | Defect | Pieces | Share | Cumulative |
|---|---|---|---|---|
| FL | Flash | 53,470 | 33.1% | 33.1% |
| SS | Short shot | 53,058 | 32.8% | 65.9% |
| SK | Sink mark | 21,934 | 13.6% | 79.5% |
| BL | Black specks | 13,306 | 8.2% | 87.7% |
| DM | Dimensional | 9,991 | 6.2% | 93.9% |
| CT | Contamination | 9,912 | 6.1% | 100.0% |
3. Downtime
Minutes from the shift spreadsheet only (ERP has no downtime). Free-text reasons mapped to five classes; unmapped text is 'Other'.
ChangeoverBreakdownMaterialQuality holdOther
Downtime minutes by machine and class.
| Class | Minutes | Share |
|---|---|---|
| Changeover | 3,905 | 47.4% |
| Breakdown | 1,820 | 22.1% |
| Material | 1,360 | 16.5% |
| Quality hold | 715 | 8.7% |
| Other | 430 | 5.2% |
Table: downtime by machine and class
| Machine | Changeover | Breakdown | Material | Quality hold | Other | Total |
|---|---|---|---|---|---|---|
| IM-01 | 880 | 540 | 320 | 285 | 50 | 2,075 |
| IM-02 | 1,015 | 390 | 210 | 170 | 255 | 2,040 |
| IM-03 | 1,135 | 260 | 555 | 110 | 15 | 2,075 |
| IM-04 | 875 | 630 | 275 | 150 | 110 | 2,040 |
4. Output reconciliation
112 work orders. Spreadsheet total before checks 2,819,124, after checks 2,920,686, ERP confirmed 2,949,353. 106 work orders agree within 2% after checks; their ERP total, 2,863,539, is the trusted figure.
Work orders by reconciliation result.
| Work order | Date | Machine | Product | Sheet raw | Sheet after checks | ERP | Diff after | Reason |
|---|---|---|---|---|---|---|---|---|
| WO-260016 | 2026-08-06 | IM-04 | P-1002 | 9,557 | 9,557 | 9,557 | +0 | late_entry |
| WO-260018 | 2026-08-07 | IM-02 | P-1001 | 12,827 | 9,502 | 9,502 | +0 | duplicate |
| WO-260023 | 2026-08-08 | IM-03 | P-1002 | 5,685 | 5,685 | 8,683 | -2,998 | missing_shift |
| WO-260028 | 2026-08-09 | IM-04 | P-1001 | 6,649 | 6,649 | 10,074 | -3,425 | missing_shift |
| WO-260030 | 2026-08-10 | IM-02 | P-1004 | 5,376 | 43,008 | 43,019 | -11 | shot_error |
| WO-260034 | 2026-08-11 | IM-02 | P-1007 | 2,726 | 10,904 | 10,907 | -3 | shot_error |
| WO-260038 | 2026-08-12 | IM-02 | P-1007 | 2,801 | 11,204 | 11,208 | -4 | shot_error |
| WO-260042 | 2026-08-13 | IM-02 | P-1001 | 2,611 | 10,444 | 10,449 | -5 | shot_error |
| WO-260046 | 2026-08-14 | IM-02 | P-1001 | 2,331 | 9,324 | 9,330 | -6 | shot_error |
| WO-260050 | 2026-08-15 | IM-02 | P-1004 | 5,485 | 43,880 | 43,896 | -16 | shot_error |
| WO-260052 | 2026-08-15 | IM-04 | P-1001 | 6,780 | 6,780 | 10,031 | -3,251 | missing_shift |
| WO-260054 | 2026-08-16 | IM-02 | P-1004 | 4,904 | 39,232 | 39,242 | -10 | shot_error |
| WO-260065 | 2026-08-19 | IM-01 | P-1008 | 47,782 | 35,238 | 35,238 | +0 | duplicate |
| WO-260069 | 2026-08-20 | IM-01 | P-1008 | 45,305 | 34,703 | 34,703 | +0 | duplicate |
| WO-260076 | 2026-08-21 | IM-04 | P-1001 | 9,241 | 9,241 | 9,241 | +0 | late_entry |
| WO-260077 | 2026-08-22 | IM-01 | P-1003 | 29,852 | 29,852 | 44,831 | -14,979 | missing_shift |
| WO-260102 | 2026-08-28 | IM-02 | P-1004 | 51,267 | 37,538 | 37,538 | +0 | duplicate |
| WO-260108 | 2026-08-29 | IM-04 | P-1002 | 6,026 | 6,026 | 9,016 | -2,990 | missing_shift |
| WO-260111 | 2026-08-30 | IM-03 | P-1005 | 2,210 | 2,210 | 3,179 | -969 | missing_shift |
Table: all work orders
| Work order | Date | Machine | Sheet raw | Sheet after checks | ERP | Diff after | Reason |
|---|---|---|---|---|---|---|---|
| WO-260001 | 2026-08-03 | IM-01 | 43,305 | 43,305 | 43,305 | +0 | agree |
| WO-260002 | 2026-08-03 | IM-02 | 42,880 | 42,880 | 42,880 | +0 | agree |
| WO-260003 | 2026-08-03 | IM-03 | 9,563 | 9,563 | 9,563 | +0 | agree |
| WO-260004 | 2026-08-03 | IM-04 | 10,239 | 10,239 | 10,239 | +0 | agree |
| WO-260005 | 2026-08-04 | IM-01 | 46,222 | 46,222 | 46,222 | +0 | agree |
| WO-260006 | 2026-08-04 | IM-02 | 44,629 | 44,629 | 44,629 | +0 | agree |
| WO-260007 | 2026-08-04 | IM-03 | 9,744 | 9,744 | 9,744 | +0 | agree |
| WO-260008 | 2026-08-04 | IM-04 | 9,407 | 9,407 | 9,407 | +0 | agree |
| WO-260009 | 2026-08-05 | IM-01 | 116,677 | 116,677 | 116,677 | +0 | agree |
| WO-260010 | 2026-08-05 | IM-02 | 11,228 | 11,228 | 11,228 | +0 | agree |
| WO-260011 | 2026-08-05 | IM-03 | 2,927 | 2,927 | 2,927 | +0 | agree |
| WO-260012 | 2026-08-05 | IM-04 | 9,590 | 9,590 | 9,590 | +0 | agree |
| WO-260013 | 2026-08-06 | IM-01 | 121,352 | 121,352 | 121,352 | +0 | agree |
| WO-260014 | 2026-08-06 | IM-02 | 10,677 | 10,677 | 10,677 | +0 | agree |
| WO-260015 | 2026-08-06 | IM-03 | 3,283 | 3,283 | 3,283 | +0 | agree |
| WO-260016 | 2026-08-06 | IM-04 | 9,557 | 9,557 | 9,557 | +0 | late_entry |
| WO-260017 | 2026-08-07 | IM-01 | 35,723 | 35,723 | 35,723 | +0 | agree |
| WO-260018 | 2026-08-07 | IM-02 | 12,827 | 9,502 | 9,502 | +0 | duplicate |
| WO-260019 | 2026-08-07 | IM-03 | 8,294 | 8,294 | 8,294 | +0 | agree |
| WO-260020 | 2026-08-07 | IM-04 | 11,749 | 11,749 | 11,749 | +0 | agree |
| WO-260021 | 2026-08-08 | IM-01 | 35,760 | 35,760 | 35,760 | +0 | agree |
| WO-260022 | 2026-08-08 | IM-02 | 9,708 | 9,708 | 9,708 | +0 | agree |
| WO-260023 | 2026-08-08 | IM-03 | 5,685 | 5,685 | 8,683 | -2,998 | missing_shift |
| WO-260024 | 2026-08-08 | IM-04 | 11,351 | 11,351 | 11,351 | +0 | agree |
| WO-260025 | 2026-08-09 | IM-01 | 42,415 | 42,415 | 42,415 | +0 | agree |
| WO-260026 | 2026-08-09 | IM-02 | 40,375 | 40,375 | 40,375 | +0 | agree |
| WO-260027 | 2026-08-09 | IM-03 | 3,038 | 3,038 | 3,038 | +0 | agree |
| WO-260028 | 2026-08-09 | IM-04 | 6,649 | 6,649 | 10,074 | -3,425 | missing_shift |
| WO-260029 | 2026-08-10 | IM-01 | 41,480 | 41,480 | 41,480 | +0 | agree |
| WO-260030 | 2026-08-10 | IM-02 | 5,376 | 43,008 | 43,019 | -11 | shot_error |
| WO-260031 | 2026-08-10 | IM-03 | 3,163 | 3,163 | 3,163 | +0 | agree |
| WO-260032 | 2026-08-10 | IM-04 | 10,206 | 10,206 | 10,206 | +0 | agree |
| WO-260033 | 2026-08-11 | IM-01 | 120,526 | 120,526 | 120,526 | +0 | agree |
| WO-260034 | 2026-08-11 | IM-02 | 2,726 | 10,904 | 10,907 | -3 | shot_error |
| WO-260035 | 2026-08-11 | IM-03 | 9,318 | 9,318 | 9,318 | +0 | agree |
| WO-260036 | 2026-08-11 | IM-04 | 9,019 | 9,019 | 9,019 | +0 | agree |
| WO-260037 | 2026-08-12 | IM-01 | 123,549 | 123,549 | 123,549 | +0 | agree |
| WO-260038 | 2026-08-12 | IM-02 | 2,801 | 11,204 | 11,208 | -4 | shot_error |
| WO-260039 | 2026-08-12 | IM-03 | 8,860 | 8,860 | 8,860 | +0 | agree |
| WO-260040 | 2026-08-12 | IM-04 | 8,500 | 8,500 | 8,500 | +0 | agree |
| WO-260041 | 2026-08-13 | IM-01 | 37,478 | 37,478 | 37,478 | +0 | agree |
| WO-260042 | 2026-08-13 | IM-02 | 2,611 | 10,444 | 10,449 | -5 | shot_error |
| WO-260043 | 2026-08-13 | IM-03 | 3,053 | 3,053 | 3,053 | +0 | agree |
| WO-260044 | 2026-08-13 | IM-04 | 11,723 | 11,723 | 11,723 | +0 | agree |
| WO-260045 | 2026-08-14 | IM-01 | 36,138 | 36,138 | 36,138 | +0 | agree |
| WO-260046 | 2026-08-14 | IM-02 | 2,331 | 9,324 | 9,330 | -6 | shot_error |
| WO-260047 | 2026-08-14 | IM-03 | 3,179 | 3,179 | 3,179 | +0 | agree |
| WO-260048 | 2026-08-14 | IM-04 | 10,332 | 10,332 | 10,332 | +0 | agree |
| WO-260049 | 2026-08-15 | IM-01 | 46,397 | 46,397 | 46,397 | +0 | agree |
| WO-260050 | 2026-08-15 | IM-02 | 5,485 | 43,880 | 43,896 | -16 | shot_error |
| WO-260051 | 2026-08-15 | IM-03 | 9,199 | 9,199 | 9,199 | +0 | agree |
| WO-260052 | 2026-08-15 | IM-04 | 6,780 | 6,780 | 10,031 | -3,251 | missing_shift |
| WO-260053 | 2026-08-16 | IM-01 | 45,570 | 45,570 | 45,570 | +0 | agree |
| WO-260054 | 2026-08-16 | IM-02 | 4,904 | 39,232 | 39,242 | -10 | shot_error |
| WO-260055 | 2026-08-16 | IM-03 | 8,721 | 8,721 | 8,721 | +0 | agree |
| WO-260056 | 2026-08-16 | IM-04 | 10,121 | 10,121 | 10,121 | +0 | agree |
| WO-260057 | 2026-08-17 | IM-01 | 115,603 | 115,603 | 115,603 | +0 | agree |
| WO-260058 | 2026-08-17 | IM-02 | 10,456 | 10,456 | 10,456 | +0 | agree |
| WO-260059 | 2026-08-17 | IM-03 | 3,267 | 3,267 | 3,267 | +0 | agree |
| WO-260060 | 2026-08-17 | IM-04 | 8,642 | 8,642 | 8,642 | +0 | agree |
| WO-260061 | 2026-08-18 | IM-01 | 105,028 | 105,028 | 105,028 | +0 | agree |
| WO-260062 | 2026-08-18 | IM-02 | 10,811 | 10,811 | 10,811 | +0 | agree |
| WO-260063 | 2026-08-18 | IM-03 | 3,046 | 3,046 | 3,046 | +0 | agree |
| WO-260064 | 2026-08-18 | IM-04 | 9,095 | 9,095 | 9,095 | +0 | agree |
| WO-260065 | 2026-08-19 | IM-01 | 47,782 | 35,238 | 35,238 | +0 | duplicate |
| WO-260066 | 2026-08-19 | IM-02 | 10,266 | 10,266 | 10,266 | +0 | agree |
| WO-260067 | 2026-08-19 | IM-03 | 8,969 | 8,969 | 8,969 | +0 | agree |
| WO-260068 | 2026-08-19 | IM-04 | 11,412 | 11,412 | 11,412 | +0 | agree |
| WO-260069 | 2026-08-20 | IM-01 | 45,305 | 34,703 | 34,703 | +0 | duplicate |
| WO-260070 | 2026-08-20 | IM-02 | 8,941 | 8,941 | 8,941 | +0 | agree |
| WO-260071 | 2026-08-20 | IM-03 | 8,647 | 8,647 | 8,647 | +0 | agree |
| WO-260072 | 2026-08-20 | IM-04 | 11,309 | 11,309 | 11,309 | +0 | agree |
| WO-260073 | 2026-08-21 | IM-01 | 45,106 | 45,106 | 45,106 | +0 | agree |
| WO-260074 | 2026-08-21 | IM-02 | 38,482 | 38,482 | 38,482 | +0 | agree |
| WO-260075 | 2026-08-21 | IM-03 | 3,266 | 3,266 | 3,266 | +0 | agree |
| WO-260076 | 2026-08-21 | IM-04 | 9,241 | 9,241 | 9,241 | +0 | late_entry |
| WO-260077 | 2026-08-22 | IM-01 | 29,852 | 29,852 | 44,831 | -14,979 | missing_shift |
| WO-260078 | 2026-08-22 | IM-02 | 41,284 | 41,284 | 41,284 | +0 | agree |
| WO-260079 | 2026-08-22 | IM-03 | 3,164 | 3,164 | 3,164 | +0 | agree |
| WO-260080 | 2026-08-22 | IM-04 | 9,737 | 9,737 | 9,737 | +0 | agree |
| WO-260081 | 2026-08-23 | IM-01 | 112,950 | 112,950 | 112,950 | +0 | agree |
| WO-260082 | 2026-08-23 | IM-02 | 11,648 | 11,648 | 11,648 | +0 | agree |
| WO-260083 | 2026-08-23 | IM-03 | 8,637 | 8,637 | 8,637 | +0 | agree |
| WO-260084 | 2026-08-23 | IM-04 | 9,562 | 9,562 | 9,562 | +0 | agree |
| WO-260085 | 2026-08-24 | IM-01 | 113,801 | 113,801 | 113,801 | +0 | agree |
| WO-260086 | 2026-08-24 | IM-02 | 10,776 | 10,776 | 10,776 | +0 | agree |
| WO-260087 | 2026-08-24 | IM-03 | 9,438 | 9,438 | 9,438 | +0 | agree |
| WO-260088 | 2026-08-24 | IM-04 | 9,915 | 9,915 | 9,915 | +0 | agree |
| WO-260089 | 2026-08-25 | IM-01 | 35,882 | 35,882 | 35,882 | +0 | agree |
| WO-260090 | 2026-08-25 | IM-02 | 9,549 | 9,549 | 9,549 | +0 | agree |
| WO-260091 | 2026-08-25 | IM-03 | 3,185 | 3,185 | 3,185 | +0 | agree |
| WO-260092 | 2026-08-25 | IM-04 | 11,100 | 11,100 | 11,100 | +0 | agree |
| WO-260093 | 2026-08-26 | IM-01 | 37,195 | 37,195 | 37,195 | +0 | agree |
| WO-260094 | 2026-08-26 | IM-02 | 9,947 | 9,947 | 9,947 | +0 | agree |
| WO-260095 | 2026-08-26 | IM-03 | 2,853 | 2,853 | 2,853 | +0 | agree |
| WO-260096 | 2026-08-26 | IM-04 | 10,869 | 10,869 | 10,869 | +0 | agree |
| WO-260097 | 2026-08-27 | IM-01 | 43,830 | 43,830 | 43,830 | +0 | agree |
| WO-260098 | 2026-08-27 | IM-02 | 41,209 | 41,209 | 41,209 | +0 | agree |
| WO-260099 | 2026-08-27 | IM-03 | 8,720 | 8,720 | 8,720 | +0 | agree |
| WO-260100 | 2026-08-27 | IM-04 | 9,148 | 9,148 | 9,148 | +0 | agree |
| WO-260101 | 2026-08-28 | IM-01 | 43,358 | 43,358 | 43,358 | +0 | agree |
| WO-260102 | 2026-08-28 | IM-02 | 51,267 | 37,538 | 37,538 | +0 | duplicate |
| WO-260103 | 2026-08-28 | IM-03 | 7,963 | 7,963 | 7,963 | +0 | agree |
| WO-260104 | 2026-08-28 | IM-04 | 10,105 | 10,105 | 10,105 | +0 | agree |
| WO-260105 | 2026-08-29 | IM-01 | 121,493 | 121,493 | 121,493 | +0 | agree |
| WO-260106 | 2026-08-29 | IM-02 | 10,246 | 10,246 | 10,246 | +0 | agree |
| WO-260107 | 2026-08-29 | IM-03 | 3,214 | 3,214 | 3,214 | +0 | agree |
| WO-260108 | 2026-08-29 | IM-04 | 6,026 | 6,026 | 9,016 | -2,990 | missing_shift |
| WO-260109 | 2026-08-30 | IM-01 | 119,789 | 119,789 | 119,789 | +0 | agree |
| WO-260110 | 2026-08-30 | IM-02 | 10,933 | 10,933 | 10,933 | +0 | agree |
| WO-260111 | 2026-08-30 | IM-03 | 2,210 | 2,210 | 3,179 | -969 | missing_shift |
| WO-260112 | 2026-08-30 | IM-04 | 9,195 | 9,195 | 9,195 | +0 | agree |
5. How the numbers were computed
- Source-of-truth rules. Defect classification: ERP. Downtime: spreadsheet only. Output: ERP confirmed quantity, cross-checked against the corrected spreadsheet.
- Dates. Format detected per file from rows where day > 12; ambiguous rows follow the file format.
- Products. Names mapped to part numbers through the client product master; unmapped rows are listed, never guessed.
- Duplicates. Same date, shift, machine and product: first row kept.
- Coverage. Planned shift calendar × machines minus rows present.
- Units. pieces = kg × 1000 / master weight (g). Master weights older than 12 months are flagged; their piece counts are approximate.
- Plausibility. ratio = (produced + scrap) / (run minutes × 60 / cycle s × cavities). Below 0.5 is treated as a shot count and multiplied by cavities; above 1.1 is flagged. Corrected rows are estimates.
- Downtime classes. Keyword dictionary (English and Turkish spellings); anything else is 'Other'.
- Agreement. A work order agrees when |sheet after checks − ERP| ≤ 2% of ERP.
- Scrap cross-check. Spreadsheet scrap 151,897 pcs vs ERP-derived 161,671 pcs (+9,774). 111,044 of the ERP pieces come from products with a stale weight master.
- Limits. No cycle-time or cavity changes within the period are modelled; corrected rows are marked and should be confirmed by the plant; this report does not estimate cost or savings. Assumes one work order per machine per day, joined on date and machine; a plant that runs more than one work order per machine per day needs a work-order column in the shift log to join correctly.
6. Files
- Raw: shift_log.csv
- Raw: erp_scrap.csv
- Raw: erp_output.csv
- Master: products.csv
- Clean: shift_log_clean.csv
- Clean: erp_scrap_pcs.csv
- Clean: work_orders.csv
Prepared by ProdCrest. AI-assisted analysis with human review. Synthetic data.