Warnings minutes-to-hours before the line actually stops.
The Sentinel watches high-frequency micro-signals — cycle time drift, tightening-gun retries, scanner re-reads, heartbeat jitter — and turns them into a per-station Risk Score. It surfaces a warning while the line is still running, not after it has already gone line stop.
Live: Station 02 over the last 8 minutes.
Risk Score: 71 (warning band entered 4 min ago). • Cycle time drift: +18% vs baseline, 5 consecutive cycles over target. • the scanner retry rate: 3.2× baseline. • Heartbeat jitter on the tightening tool: normal. Suspected mode: scanner degradation. Estimated lead time to stoppage: 6–14 min. Suggested action: reseat the scanner or fall back to manual scan.
Live: station Station 03 — risk trend over the shift.
Risk Score climbed from 22 → 58 over the last 90 min. • Dominant signal: rising tightening-retry rate on the tightening tool (now 2.4× baseline). • Secondary: small upward drift in cycle time (+6%). Suspected mode: hardware degradation on the tightening tool. Estimated lead time to stoppage: 25–60 min. Suggested action: schedule a tool swap at the next planned changeover, not mid-shift.