Operators log shift data into the Access QC Management database: uptime/downtime percentages per shift (Day/Swing/Night), tank levels, feed rates, production rates, equipment settings. 3 shifts x 5 days = 15 entries per plant per week.
QC operators run 3-4 sieve tests per day, entering particle size distributions across 10 mesh sizes with spec compliance checking. ~15,000-20,000 entries per year across all plants. Results logged separately from production data.
Operations manager exports last week's data from Access database. Navigates through individual entries using InfoMode button, copies values manually into the 2025 WW & WD Production Report Excel workbook (66 tabs).
Excel formulas convert shift percentages to minutes (% x 0.01 x 479), then to hours (/60). Sums across all shifts for weekly totals across 8 downtime categories: PRO, SCH, USM, USP, SMT, WEA, OTR, SUT/SDT.
Average TPH rates per stacker (1-5 + County) multiplied by uptime hours to derive weekly production. Green boxes in Excel = manual entries from other reports. Cross-referencing belt scale data, inventory measurements, and production logs.
Weekly data aggregated into monthly report tabs. KPIV tracking for Crusher (target 180 TPH), Polydeck (130), Hydrosorts (110), Feed Loader (250). Median calculations, chart generation, comparison against targets.
Operators present monthly performance to management and team members. Each department prepares their own section. Data must be formatted for presentation outside of the Excel report.
At year end, the entire 66-tab workbook is duplicated and reset for the new year. All weekly tabs cleared, formulas preserved, new year headers updated. YTD tabs reset.
Web-based forms replace Access 2010. Same familiar data points, cleaner interface. Tablet/desktop optimized. Auto-saves, validates entries in real-time, flags missing or inconsistent data before submission. Guided downtime categorization with definitions and examples.
Sieve tests entered in same platform. Instant spec compliance visualization. When results drift out of spec, automatic notification sent to hydrosort operator with current settings context. Historical comparison: "Last time this happened, adjustment X corrected it."
The moment data is entered, all calculations fire automatically. Percentage-to-hours conversion (x 0.01 x 479 / 60), weekly aggregation across all shifts, tonnage derivation (TPH x uptime hours), KPIV tracking against targets. Zero manual Excel work.
Real-time view of all four plants: tank levels, production rates, uptime/downtime, current shift performance. Color-coded status indicators. KPIV gauges showing Crusher, Polydeck, Hydrosorts, and Feed Loader performance against targets (180, 130, 110, 250 TPH).
Reports generate themselves from live data. Weekly production summaries, monthly rollups with trend charts, YTD comparisons. KPIV medians and trend analysis. Exportable to PDF. Emailed to leadership on schedule. Formatted for presentation.
System monitors production metrics against historical baselines. Flags unusual downtime patterns, TPH drops, spec failures. Alerts sent to relevant personnel. "Stacker 2 TPH dropped below 40 for the first time in 3 weeks - investigate?"
Operators still make the judgment calls: hydrosort pressure adjustments, blend decisions, feed assessments. The system captures every decision with context and outcomes, building an institutional knowledge base over time.
Historical production data feeds a capacity model. "If we grow turf sand by 20%, what does that require from the wet plant?" What-if simulator using actual production rates, current utilization, and sales projections. Click-of-a-button scenario analysis.
| Process Area | Current | AI-Powered | Impact |
|---|---|---|---|
| Data entry platform | Access 2010 (unsupported) | Cloud web app | Eliminates platform risk |
| Weekly report generation | 2-3 hrs manual Excel work | Automatic, instant | ~10 hrs/month saved |
| Monthly rollup and KPIV | 4-5 hrs across departments | Auto-generated with trends | ~5 hrs/month saved |
| Presentation preparation | 1 hr per dept per month | Pre-built dashboards, exportable | ~4 hrs/month saved |
| Historical analysis | Click through 25+ entries manually | Search, filter, visualize in seconds | Hours to seconds |
| QC-to-production feedback | Manual, delayed communication | Instant alerts with context | Faster quality corrections |
| Downtime pattern visibility | Only visible after monthly assembly | Real-time trend monitoring | Proactive maintenance |
| Capacity planning | Manual Excel model, limited scenarios | What-if simulator with live data | Strategic growth tool |
| Knowledge continuity | Concentrated in key personnel | Codified in system with audit trail | Succession-ready / PE value |
| Annual workbook reset | 2-3 hours, error-prone | Continuous, no resets | Eliminated entirely |
| Total monthly time savings | 30+ hours/month | <5 hours/month | ~25+ hours/month freed |