Quality Health Score
First Pass Yield
OK Ratio
NG Ratio
Defect PPM
COPQ Impact™
Quality Overview
Factory → Line → Machine → Mold quality hierarchy
Factory FPY
94.2%
Factory PPM
4,820
Scrap Rate
1.8%
Rework Rate
3.1%
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
OK vs NG Intelligence
Drill-down: NG → Machine → Mold → Product → Shift → Operator
| Machine | OK Qty | NG Qty | NG Rate | Status |
|---|---|---|---|---|
| MC-01 | 2,798 | 42 | 1.5% | Normal |
| MC-02 | 1,224 | 16 | 1.3% | Normal |
| MC-03 | 5,496 | 124 | 2.2% | Critical |
| MC-05 | 12,202 | 198 | 1.6% | Monitor |
| MC-06 | 7,938 | 162 | 2.0% | Monitor |
| MC-08 | 945 | 15 | 1.6% | Monitor |
| MC-09 | 7,056 | 144 | 2.0% | Monitor |
| MC-10 | 3,639 | 41 | 1.1% | Normal |
| MC-11 | 4,026 | 74 | 1.8% | Monitor |
NG Analysis Center
Injection & rubber defect Pareto, trend, and cost analysis
Pareto — Defect Frequency
NG Rate Trend — This Week (%)
| Defect Type | Count | Share % | Cost (Rp) | Trend | Top Machines |
|---|---|---|---|---|---|
| Flash | 312 | 28.2% | Rp 4.7M | ↑ Rising | MC-03, MC-07 |
| Short Shot | 198 | 17.9% | Rp 3.0M | ↑ Rising | MC-07, MC-09 |
| Sink Mark | 164 | 14.8% | Rp 2.5M | → Stable | MC-02, MC-08 |
| Burn Mark | 112 | 10.1% | Rp 1.7M | ↓ Falling | MC-06, MC-11 |
| Flow Mark | 98 | 8.9% | Rp 1.5M | → Stable | MC-01, MC-05 |
| Weld Line | 76 | 6.9% | Rp 1.1M | → Stable | MC-03, MC-06 |
| Silver Streak | 62 | 5.6% | Rp 0.9M | ↑ Rising | MC-09, MC-11 |
| Black Spot | 44 | 4.0% | Rp 0.7M | ↓ Falling | MC-02 |
| Warpage | 24 | 2.2% | Rp 0.4M | → Stable | MC-08 |
| Crack | 16 | 1.4% | Rp 0.2M | ↓ Falling | MC-10 |
COPQ Intelligence
Cost of Poor Quality breakdown by category, product, machine, and customer
Rp 6.3M
22.2% of COPQ
420 kg scrapped material × avg Rp 15,000/kg
Rp 8.1M
28.5% of COPQ
1,240 pcs reworked × avg Rp 6,500/pcs labor
Rp 5.6M
19.7% of COPQ
8 active warranty claims this month
Rp 8.4M
29.6% of COPQ
3 claims: Toyota (Rp 4.2M), Honda (Rp 2.8M), Daihatsu (Rp 1.4M)
Total COPQ Impact™ — Today
Shift 1 · Plant Karawang · 12 Jun 2026
Rp 28.4M
+18.6% vs last week avg
COPQ Breakdown by Product (Rp M)
Supplier Quality Intelligence
Incoming material PPM, ranking, and NCR status
Active Suppliers
24
Above PPM Limit
3
Avg Incoming Pass
98.6%
Open NCRs
7
| Rank | Supplier | Material | PPM | vs Target | Incoming % | Trend | Status | |
|---|---|---|---|---|---|---|---|---|
| #1 | PT Chandra Asri Polymers | PP-HM, ABS | 840 | 500 | 98.4% | -12 ppm | Monitor | |
| #2 | PT Asahimas Chemical | PVC, CPVC | 320 | 500 | 99.6% | -8 ppm | Approved | |
| #3 | PT Mitsui Chemicals | PA66, POM | 1,240 | 500 | 97.2% | +24 ppm | Critical | |
| #4 | PT Toyo Ink Indonesia | Masterbatch | 480 | 500 | 99.1% | -4 ppm | Approved | |
| #5 | PT DIC Graphics | Pigment, Additive | 620 | 500 | 98.8% | +6 ppm | Monitor | |
| #6 | PT Lanxess Indonesia | EPDM Rubber | 1,680 | 500 | 96.4% | +42 ppm | Critical |
AI Quality Copilot
Powered by defect data, COPQ analysis, and supplier history