Root Cause Analysis Agent

Ask why. Get the root cause, evidence, and fix.

This is a real diagnosis, replayed. One question from the plant floor — and Morale traces it through sensors, MES records, and maintenance history.

Why did Line 3's OEE drop last week, and which root causes should we fix first?

You · Plant Ops · 09:41
I traced the drop to bearing wear on Station 4 94% confidence — the vibration signature shifted at 14:22 on July 3 and matches a known degradation pattern. Here's your week at a glance:
OEE
83.2%
▼ 4.1 pts vs prior wk
Unplanned downtime
6.8h
▲ 2.3 h vs prior wk
Scrap rate
1.9%
▲ 0.4 pts vs prior wk
MTTR
42min
▼ 18% agent triage
Morale RCA Agent · 09:42
This is the moment it began. RMS velocity held a 2.3 mm/s baseline all morning, then jumped past the 3.5 alert threshold at 14:22 — and stayed there:

Vibration signature — Station 4 spindle

RMS velocity (mm/s) · July 3 · sensor VIB-04-2

View data as table
TimeRMS (mm/s)State
06:00–14:002.1–2.6Normal
14:224.9Shift detected
14:30–18:004.6–5.2Above 3.5 threshold
Morale RCA Agent · 09:42
Bearing wear cost you 2.6 of the 6.8 lost hours. The rest of the week breaks down like this:

Downtime by contributor

Last 7 days · Line 3 · 6.8 h total

View data as table
ContributorDowntime (h)Share
Bearing wear — Station 42.638%
Feeder jam — Station 21.421%
Tool change overrun1.116%
Material wait0.913%
Sensor fault — E-stop 70.57%
Other0.35%
Morale RCA Agent · 09:43

What should we fix first, and what does it save us?

You · Plant Ops · 09:44
Start with the bearing. I found the same signature in maintenance log #ML-2023-0614 on Line 1 — bearing replacement plus lubrication adjustment resolved it, and parts are already on site.

Replace Station 4 spindle bearing

SCHEDULE WITHIN 48 H · NEXT PLANNED STOP: THU 06:00
Planned stop
2 h
Unplanned risk avoided
~9 h
Est. OEE recovery
+3.8 pts

Evidence: VIB-04-2 sensor stream · MES downtime events · log #ML-2023-0614 — every step traceable to your data.

Morale RCA Agent · 09:45

Great — can you summarize all of this into one dashboard for the morning meeting?

You · Plant Ops · 09:46
Done — the full analysis in one view. Expand it whenever you need the detail:
OEE
83.2%
▼ 4.1 pts vs prior wk
Unplanned downtime
6.8h
▲ 2.3 h vs prior wk
Scrap rate
1.9%
▲ 0.4 pts vs prior wk
MTTR
42min
▼ 18% agent triage

Downtime by root cause

Hours lost · identified cause highlighted

Vibration signature — Station 4

RMS mm/s · July 3 · shift at 14:22

Evidence trail

Every step traceable to your data

Root cause identified — bearing wear, 94% confidence

14:22 vibration shift on Station 4 matches a bearing degradation signature across 3 sensors.

Similar case — log #ML-2023-0614

Identical pattern on Line 1. Resolved with bearing replacement + lubrication adjustment.

Action — replace bearing within 48 h

2 h planned stop vs ~9 h unplanned risk. Est. OEE recovery +3.8 pts.

Downtime by contributor

6.8 h total · last 7 days

Morale RCA Agent · 09:46

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