Monitoring & Escalation

KPI Alarm System

Preset KPI limits per department with live severity, plus AI-recommended KPIs you can activate. Breaches raise warning or critical alarms, can be acknowledged with an audit entry, and feed the AI agents as operational context.

Active alarms
31
unacknowledged breaches
Critical
10
immediate escalation
Warning
21
watch level
Monitored KPIs
32
13 departments
Acknowledged
0
with audit trail

Active alarms

  • OTIF (on time in full)Critical
    Executive · actual 91.4 % vs limit 92 % (min) · Board target 95%
  • Gross marginPending
    Executive · actual 38.6 % vs limit 36 % (min) · Budget 39%
  • Open critical risksCritical
    Executive · actual 17 vs limit 8 (max) · Enterprise risk policy
  • Forecast accuracy (MAPE)Pending
    Planning · actual 17.8 % vs limit 22 % (max) · S&OP policy ≤15%
  • Days of inventory coverPending
    Planning · actual 118 days vs limit 130 days (max) · Working capital target 90–100 d
  • POs at high delay riskCritical
    Procurement · actual 8 vs limit 6 (max) · Supply continuity policy
  • Qualified supplier coverageCritical
    Procurement · actual 93.2 % vs limit 95 % (min) · EU GMP Ch.5 supplier control
  • OEEPending
    Manufacturing · actual 74.6 % vs limit 70 % (min) · Site target 78%
  • Batch yield variancePending
    Manufacturing · actual 2.1 % vs limit 3 % (max) · Master formula tolerance ±2%
  • Right first time (EBR)Pending
    Manufacturing · actual 88.5 % vs limit 85 % (min) · Data integrity KPI
  • Batches awaiting QA releaseCritical
    Quality · actual 13 vs limit 9 (max) · Release SLA 3 working days
  • Open critical deviationsCritical
    Quality · actual 9 vs limit 3 (max) · EU GMP Ch.1 quality system
  • Overdue CAPAsCritical
    Quality · actual 5 vs limit 5 (max) · CAPA SOP QA-014
  • OOS ratePending
    Quality · actual 1.4 % vs limit 2 % (max) · QC trending SOP
  • Near-expiry stock exposureCritical
    Warehouse · actual 71.6 EGP M vs limit 40 EGP M (max) · Write-off provision policy
  • FEFO compliancePending
    Warehouse · actual 96.1 % vs limit 95 % (min) · GDP Annex FEFO rule
  • Cycle count accuracyPending
    Warehouse · actual 98.7 % vs limit 97 % (min) · GxP inventory SOP
  • Cold-chain excursionsPending
    Distribution · actual 3 vs limit 5 (max) · GDP temperature control
  • Average delivery lead timePending
    Distribution · actual 41 hours vs limit 48 hours (max) · Service policy 36 h
  • Orders on credit holdPending
    Commercial · actual 5 vs limit 8 (max) · Credit policy
  • DSOPending
    Finance · actual 71 days vs limit 75 days (max) · Treasury target 60 d
  • Cost variance (unfavourable)Pending
    Finance · actual 4.9 EGP M vs limit 6 EGP M (max) · Controlling tolerance
  • Overdue receivables > 30 dPending
    Finance · actual 22.8 % vs limit 25 % (max) · Credit policy
  • Instruments overdue calibrationPending
    Engineering · actual 2 vs limit 3 (max) · Calibration SOP ENG-007
  • Critical asset uptimePending
    Engineering · actual 96.4 % vs limit 94 % (min) · Maintenance plan
  • Licences expiring < 90 daysPending
    Regulatory · actual 4 vs limit 6 (max) · Regulatory calendar
  • GxP training complianceCritical
    Regulatory · actual 94.3 % vs limit 95 % (min) · Training SOP HR-002
  • Interface failure ratePending
    IT & Automation · actual 0.8 % vs limit 2 % (max) · Integration SLA
  • Audit trail completenessPending
    IT & Automation · actual 99.6 % vs limit 99 % (min) · 21 CFR Part 11
  • Master data completenessCritical
    Master Data · actual 92.8 % vs limit 95 % (min) · Data governance policy
  • Duplicate master recordsPending
    Master Data · actual 7 vs limit 15 (max) · Data governance policy

Preset KPI thresholds

KPIDepartmentActualWarningCriticalStateAlarm
OTIF (on time in full)
Customer orders delivered complete and on date.
Executive91.4 %Critical
Gross margin
Consolidated gross margin, month to date.
Executive38.6 %Pending
Open critical risks
Critical deviations, recalls and supply risks open now.
Executive17Critical
Forecast accuracy (MAPE)
Mean absolute % error of the demand forecast.
Planning17.8 %Pending
Days of inventory cover
Finished goods cover against the rolling plan.
Planning118 daysPending
POs at high delay risk
Open purchase orders flagged high delay risk by the AI agent.
Procurement8Critical
Qualified supplier coverage
Spend covered by suppliers with valid GxP qualification.
Procurement93.2 %Critical
OEE
Overall equipment effectiveness across packaging lines.
Manufacturing74.6 %Pending
Batch yield variance
Deviation of actual yield from the master formula yield.
Manufacturing2.1 %Pending
Right first time (EBR)
Batch records closed with no correction.
Manufacturing88.5 %Pending
Batches awaiting QA release
Batches sitting in QA review beyond the release SLA.
Quality13Critical
Open critical deviations
Critical classified deviations not yet closed.
Quality9Critical
Overdue CAPAs
CAPA actions past their committed due date.
Quality5Critical
OOS rate
Out-of-specification results as % of tests performed.
Quality1.4 %Pending
Near-expiry stock exposure
Value of lots expiring within 90 days.
Warehouse71.6 EGP MCritical
FEFO compliance
Picks executed against the first-expiry lot.
Warehouse96.1 %Pending
Cycle count accuracy
Bin-level inventory accuracy from cycle counting.
Warehouse98.7 %Pending
Cold-chain excursions
Shipments with a temperature excursion in the last 30 days.
Distribution3Pending
Average delivery lead time
Order release to customer delivery.
Distribution41 hoursPending
Orders on credit hold
Sales orders blocked on credit exposure.
Commercial5Pending
Sales target attainment
Net sales versus target, month to date.
Commercial104.9 %Passed
DSO
Days sales outstanding on trade receivables.
Finance71 daysPending
Cost variance (unfavourable)
Actual versus standard batch cost, month to date.
Finance4.9 EGP MPending
Overdue receivables > 30 d
Share of AR older than 30 days.
Finance22.8 %Pending
Instruments overdue calibration
GxP instruments past their calibration due date.
Engineering2Pending
Critical asset uptime
Availability of qualified critical equipment.
Engineering96.4 %Pending
Licences expiring < 90 days
Marketing authorisations and site licences near expiry.
Regulatory4Pending
GxP training compliance
Staff current on their assigned GxP curriculum.
Regulatory94.3 %Critical
Interface failure rate
Failed messages on the MES / LIMS / SAP bus.
IT & Automation0.8 %Pending
Audit trail completeness
Transactions carrying a complete ALCOA+ audit entry.
IT & Automation99.6 %Pending
Master data completeness
Products, materials and partners with all mandatory GxP attributes.
Master Data92.8 %Critical
Duplicate master records
Suspected duplicates detected by the data quality agent.
Master Data7Pending

Thresholds are per-department presets derived from GxP policies and site targets; edits persist locally and are written to the audit trail on acknowledgement. Direction "max" alarms when the value rises above the limit, "min" when it drops below.

AI-recommended KPIs

Cash conversion cyclePending
Executive

DIO + DSO − DPO across the group.

Why: Inventory cover and DSO are both above target — a combined cycle KPI exposes the working-capital trend earlier.

Current 132 daysProposed warn 120 daysCritical 150 daysTreasury benchmark
Forecast biasPending
Planning

Signed forecast error showing systematic over/under planning.

Why: MAPE alone hides direction; bias explains the rising inventory cover.

Current 6.4 %Proposed warn 5 %Critical 10 %S&OP best practice
Single-sourced API spendPending
Procurement

Spend on APIs with only one qualified supplier.

Why: Imported API delays are the top supply risk driver this quarter.

Current 34 %Proposed warn 25 %Critical 40 %Supply resilience policy
Changeover / cleaning timePending
Manufacturing

Average validated cleaning + changeover duration per line.

Why: Largest single contributor to the OEE gap on Line 3.

Current 214 minutesProposed warn 180 minutesCritical 240 minutesCleaning validation study
QA release cycle timePending
Quality

Batch completion to release decision.

Why: Counting the queue is lagging; cycle time detects the slowdown before the queue builds.

Current 4.6 daysProposed warn 3 daysCritical 6 daysRelease SLA
Repeat deviation ratePending
Quality

Deviations recurring on the same root cause within 12 months.

Why: Directly measures CAPA effectiveness — a common inspection finding.

Current 18 %Proposed warn 10 %Critical 20 %CAPA effectiveness review
Expiry write-off ratePending
Warehouse

Value written off for expiry versus stock value.

Why: Converts the near-expiry exposure alarm into realised financial loss tracking.

Current 1.9 %Proposed warn 1 %Critical 3 %Provision policy
Cold-chain mean kinetic temperaturePending
Distribution

MKT of monitored lanes over 30 days.

Why: Excursion counts miss slow drift; MKT catches lane degradation.

Current 6.4 °CProposed warn 6 °CCritical 8 °CGDP Annex
Customer churn risk valuePending
Commercial

Revenue at risk from accounts flagged by the churn agent.

Why: Turns the AI churn signals into a monitored, escalating alarm.

Current 23.5 EGP MProposed warn 15 EGP MCritical 30 EGP MCommercial plan
Landed cost deviation on importsPending
Finance

Actual versus planned landed cost on imported API.

Why: FX and freight drive most of the current unfavourable cost variance.

Current 8.2 %Proposed warn 5 %Critical 10 %Controlling tolerance
MTBF on critical assetsPending
Engineering

Mean time between failures for qualified critical equipment.

Why: Predictive maintenance alerts need a reliability baseline to be actionable.

Current 640 hoursProposed warn 720 hoursCritical 500 hoursReliability plan
Inspection finding response timePending
Regulatory

Days to submit a response to an inspection observation.

Why: Late responses escalate observations; time-based alarming prevents it.

Current 21 daysProposed warn 15 daysCritical 30 daysAuthority commitment
SAP sync latencyPending
IT & Automation

Age of the newest successfully synced SAP record.

Why: Stale master data silently corrupts planning and costing runs.

Current 34 minutesProposed warn 15 minutesCritical 60 minutesIntegration SLA
Master data change lead timePending
Master Data

Request to approved change on GxP master records.

Why: Slow master data changes are the root cause of most planning exceptions.

Current 5.2 daysProposed warn 3 daysCritical 7 daysData governance policy