Assessment – AIBI

Section 1 of 5

Data Accessibility

How easily can your team get to the data they need?

How long does it take a production engineer to answer the question "What was our scrap rate on Part X last month?"

A Under 5 minutes. They can pull it from a system directly. B 30 minutes to 2 hours. They need to export data, combine spreadsheets, or ask someone in quality. C Half a day or more. It requires pulling records from multiple places, and some of the data might not be digital.

Can a floor supervisor check the current status of a work order without walking to a computer terminal or asking someone else?

A Yes. Mobile access, floor displays, or integrated dashboards are available. B Sort of. They can check on a shared terminal, but it requires logging in and navigating to the right screen. C No. They ask the scheduler or check the paper traveler.

If a customer calls and asks for a certificate of conformance or traceability record for a shipment from six months ago, how long does it take to produce it?

A Minutes. Records are digital, linked to the job, and retrievable through the system. B A few hours. Someone needs to locate the files, which are stored digitally but not well-organized or linked. C A day or more. It involves searching filing cabinets, paper records, or asking the quality manager to reconstruct it.

How many different system logins does a typical engineer need to answer a question that spans production, quality, and maintenance?

A One or two. Systems are integrated or there is a unified access point. B Three to five. Each department has its own system. C More than five, or some of the data is not in any system at all.

Do your operators and engineers ask fewer questions than they should because getting the answer is too hard?

A No. People ask questions freely and get answers quickly. B Probably. We know there are questions people have stopped asking, but the workarounds have become normal. C Definitely. We make a lot of decisions based on gut feel because pulling data takes too long to be practical.

Section 2 of 5

System Integration

How well do your systems work together?

When a quality issue is identified, can you trace it back to the specific machine, operator, shift, material lot, and tooling setup without manual detective work?

A Yes. The data links exist and traceability is part of our standard process. B Partially. We can get some of those links, but others require manually correlating timestamps or job numbers across systems. C No. Root cause investigation is mostly manual, relying on interviews and paper records.

Does data entered in one system (for example, a completed inspection) automatically update or trigger actions in another system (for example, releasing a hold on a work order)?

A Yes, for our core workflows. Key systems are integrated and data flows between them. B In a few cases, but it is the exception. Someone usually re-enters data or manually updates the other system. C No. Each system is independent. Data entered in one stays in one.

Do you have a single, consistent part number format that works across all of your systems?

A Yes. Part numbers are standardized and consistent everywhere. B Mostly, but there are variations. The ERP uses one format, the quality system uses another, and someone maintains a crosswalk spreadsheet. C No. Part number formats vary by system, by customer, and sometimes by who entered them. It is a known problem.

Section 3 of 5

Knowledge Capture

How well does your organization preserve operational expertise?

If your most experienced setup technician retired tomorrow, how much of their knowledge is documented in a way that someone else could use?

A A significant portion. Setup procedures, tips, and institutional knowledge have been captured in a usable format. B Some of it. Standard procedures exist, but the real expertise is not written down. C Very little. We would lose months of productivity while someone else figured it out through trial and error.

When a problem gets solved on the shop floor, does that solution get recorded anywhere searchable?

A Yes. We have a system for capturing and retrieving operational knowledge, and people actually use it. B Sometimes. It might go into an email, a note in the ERP, or a conversation that gets passed along verbally. C Rarely. Solutions live in people's heads.

Do newer employees have a way to search for past solutions to problems they encounter?

A There are searchable resources that newer employees use regularly. B There are some documents, but they are incomplete or hard to find. Asking someone is still the primary method. C Asking someone is the only method. If nobody on shift knows, the problem waits.

Section 4 of 5

Data Quality

Can you trust the data you have?

How confident are you in the accuracy of the data in your ERP system (inventory counts, cycle times, routing steps, BOMs)?

A High confidence. We audit regularly, and the data is generally reliable. B Mixed. Some areas are well-maintained. Other areas have known accuracy issues that people work around. C Low confidence. We know the data has significant gaps, and people rarely trust it without double-checking.

When someone enters data into a system, is the data entry standardized, or does it vary based on who is entering it?

A Standardized. Drop-downs, validation rules, and consistent training mean the data is clean and uniform. B Somewhat standardized. There are guidelines, but free-text fields and inconsistent practices mean the data is messy in places. C It varies widely. The same defect might be entered five different ways by five different operators.

Section 5 of 5

Security & Compliance

How prepared are you for data governance and regulatory requirements?

Do you have clear, enforced rules about who can access what data?

A Yes. Role-based access controls are in place. People see what they need for their job, and sensitive data is restricted. B Partially. Some access controls exist, but they are inconsistent. C Not really. If you have a login, you can see pretty much everything.

If you were audited tomorrow, how quickly could you produce the required data and demonstrate your controls?

A We would be ready within a day. Records are organized, access is documented, and audit packages can be assembled quickly. B We would need a week of scrambling. The data exists, but pulling it together requires significant effort. C It would be a serious problem. We have gaps in documentation, access logging, or data retention that an auditor would flag.

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