Laminator 1 Vacuum Excursion · 09:34–11:04
Cluster cluster_laminator1_0934_excursion
Modules affected
11
3 Scrap · 4 B · 0 C · 4 clean
Defect rate
64%
across the cluster
Avg signature match
67%
coherence 84%
Net impact
$710
risk $1,870 − salvage $1,160
Root cause: Laminator 1 vacuum hold spike to 7.2 mbar at 09:34, against a backdrop of membrane health below 0.85 for >24 h. 11 modules processed in the 90-minute window; 7 developed bubble defects (3 Scrap + 4 B-tier), 4 escaped.
Excursion timeline · 09:34 → 11:04 · 90 min
Vacuum Hold Pressure · Laminator 1
X-bar R chart
warn 8 · action 12 mbar
Single-cycle excursion to 7.2 mbar at 09:34 (just at warning threshold). Insufficient for sustained alert but enough to lock a gas pocket into this module.
Membrane Health · Laminator 1
I-MR chart
warn 0.85 · action 0.78 index
Laminator 1 membrane has been below warning threshold (0.85) for 24+ hours, last replaced 2,650 cycles ago. Slow degradation enabled the single-cycle excursion.
Scrap with defect B/C-tier UnaffectedEach tick = one cluster module's processing time
Affected modules · 11 total
sort
mod_showcase_combined_001
Showcase#1/11 · 09:34
Scrap198
sig 81%461 W
Showcase — bubble bottom-left, single-cycle vacuum spike signature.
mod_cluster_laminator1_002
#2/11 · 09:42
Scrap198
sig 76%504 W
Bottom-left bubble.
mod_cluster_laminator1_003
#3/11 · 09:50
Scrap198
sig 72%511 W
Active-area bubble.
mod_cluster_laminator1_004
#4/11 · 09:58
Tier B198
sig 64%549 W
Smaller bubble — B-tier.
mod_cluster_laminator1_005
#5/11 · 10:06
Tier B198
sig 61%552 W
B-tier bubble.
mod_cluster_laminator1_006
#6/11 · 10:14
Tier B198
sig 59%555 W
Marginal bubble.
mod_cluster_laminator1_007
#7/11 · 10:23
Tier B198
sig 57%557 W
Small B-tier bubble.
mod_cluster_laminator1_008
#8/11 · 10:31
Tier Ano defect
sig 0%612 W
Escaped — vacuum hold settled before lamination cycle.
mod_cluster_laminator1_009
#9/11 · 10:39
Tier Ano defect
sig 0%613 W
Escaped — vacuum hold settled before lamination cycle.
mod_cluster_laminator1_010
#10/11 · 10:47
Tier Ano defect
sig 0%614 W
Escaped — vacuum hold settled before lamination cycle.
mod_cluster_laminator1_011
#11/11 · 10:55
Tier Ano defect
sig 0%615 W
Escaped — vacuum hold settled before lamination cycle.
Cluster Bayesian coherence — is this one cluster or many?
Confidence that all 11 modules share a single causal root:84%
Predicted signature
Single localized bubble in weakest seal region (bottom-left of Laminator 1 chamber)
Observed signature
7 of 11 modules show bottom-left bubble; 4 unaffected
Average signature match across affected modules: 67%. High coherence means the defects look like the same phenomenon — strong evidence of a common cause.
Economic impact
Total modules affected11
Scrap3
B-tier4
C-tier0
Unaffected (A-tier)4
Revenue at risk$1,870
Salvage realised$1,160
Net impact$710
If the platform's recommendation had been accepted at the right moment, projected savings:~$604 across this cluster.
Cluster-wide recommendations
Bring forward Laminator 1 membrane swap (do not wait for next planned downtime)
process
Membrane has been below warning threshold (0.85) for 24+ h. Continued operation risks further single-cycle excursions.
→ Eliminates the underlying mechanism for this cluster type.
Tighten X-bar R sustained-alert criteria for Laminator 1
station
Single-cycle excursions currently only logged, not alerted. They are the precursor to clusters like this.
→ Earlier detection of vacuum drift.
This cluster page shows how a single upstream excursion produces a coherent pattern across many modules. In production, every excursion that exceeds SPC thresholds is automatically grouped into a cluster, and cluster-level analysis runs continuously.