Opportunity Radar reads your reject data and ranks the five quality problems that would save the most money to fix. The top one is shown large with the reason and first step. You mark one handled and the next best problem takes its place.
Opportunity Radar
About $640,000 a year in fixable quality losses is on the board. Here are the 5 to chase first.
It watches the same reject numbers you already track and ranks the fixes that save the most money. These 5 add up to about $260,000 of the $640,000; the rest is spread across the other 33 problems. Savings are estimated from your last 90 days of reject counts times the rework and scrap cost per part.
As of June 2026, based on the last 90 days of reject data.
1It reads your reject data. The same quality numbers you already track.
2It ranks the biggest money-savers. Hardest-hitting fix first.
3You clear one, the next pops up. An AI explains why and where to start.
Start here, the number 1 fix right now
Rank 1 of 5
Plating pits on Line 49
M66 tube family
AI Why it ranks here
Biggest yearly savings, and almost all of it is one line, one part family, one supplier. And it is getting worse.
First step to check
Check the rectifier and agitation on Line 49 for that family.
Either choice clears it from the board and the next best problem moves up. The tool logs which you picked.
Savings if fixed
$88,000per year
Getting worseClear-cut cause
One line, one part family, one supplier. The cause is easy to pin down.
Next upClear this and ranks 2 to 5 each move up one, while number 6 (Plating pits on Line 37, rear shields, about $19,000 / year) joins the bottom. The board always shows 5.
Also worth your time, ranked by savingsSavings if fixed / year
2
Polish defects on Line 49, 5-inch muffler cans
Getting worseClear-cut cause
AIManual polishing cell, concentrated on the cans, climbing as new operators train. First step: review the can fixture and operator certification.
$61,000
per year
3
Etching defects on Line 38, front shields
SteadySpread across shifts
AIHighest volume of any defect, concentrated on front shields, steady but costly. First step: chase the over-etch root cause on Line 38.
$54,000
per year
4
PVD color mismatch on Line 4, Indian sprockets
Getting worseCause: less certain
AIRising, and it tracks to one chemistry lot from a single supplier. First step: verify the incoming lot.
$33,000
per year
5
Adhesion and peeling on Line 11, Harley brackets
Fastest-risingClear-cut cause
AISmallest today but the fastest-rising, and it traces to one supplier's incoming parts. First step: pre-clean and surface prep at that supplier.
$24,000
per year
Updates as new reject data comes in. When you mark one handled (or skip it), it drops off the board and the next best problem moves up to take its place.