Fit-up is where the tolerances of every earlier stage meet, and where they cost time. A part that arrives wrong, a joint that will not close, a crane committed elsewhere — each is a delay that never books as downtime, because nothing technically stopped. It lands as an assembly that took longer than it should have, with no reason attached.
Your ERP logs the assemblies fitted.
It won’t tell you the joint sat open waiting on a part that came in out of tolerance, or that the crane was committed the whole morning.
Why the gap existsWhere the losses hide
Fit-up delays and re-work do not stop a line — they stretch it. The stretch is invisible unless the reason is logged when it happens.
Waiting on a part, a crane or a fixture is real time lost with the line technically running. It comes up as fewer assemblies, with the reason gone by the time anyone asks.
A part that arrives out of tolerance sends a joint back or forces a re-work at assembly. The cost lands here, but the cause is upstream at cutting or forming.
Grinding, re-tacking and re-positioning to make a poor fit close is real labour on a part already counted, absorbed as assembly hours.
The join
Same run, same clock, same asset — three streams that only mean something together.
Assemblies fitted, and the re-work booked to the department.
The operator’s delay and mismatch reasons tagged when they happen, against the assembly and the upstream part.
Delay causes and mismatch rates read against the upstream stage that sent the part, so the time lost at assembly points back to where the fix is.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Tagged as it happens, so the lost time lands against the cause instead of the count.
The re-work happens at assembly; the cause is the stage that sent the part.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
The weld metres you logged, and the ones that quietly went back.
The coat that went on, and the part of it that went on twice.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.