Pouring is a temperature problem with a scheduling cause. Metal that sits in the ladle loses heat on a curve everyone knows, and the castings that come out short or cold-shut are the ones poured at the bottom of it. The pouring temperature is often written down; what almost never is, is why it fell.
Your ERP logs the pour: weight poured, castings made.
It won’t tell you the ladle stood for eleven minutes, or that the misruns that shift all came from the pours that followed.
Why the gap existsWhere the losses hide
A misrun is found at knockout and blamed on the pour. Its cause is usually further back and several minutes earlier.
Every minute between tap and pour costs heat. Pour at the bottom of that curve and you get misruns and cold shuts - defects that look like a pouring fault and are really a waiting fault.
The ladle waits because the crane is committed, the mould line is behind, or the next box is not ready. None of it is downtime, so none of it is recorded.
Misruns are counted at knockout against a batch, not against the pour that made them - so the pattern in the pouring log never gets connected to the pattern in the reject log.
The join
Same run, same clock, same asset — three streams that only mean something together.
Poured weight, heat number, castings produced and the rejects booked later.
Pouring temperature as logged at the ladle, the operator’s delay reason tagged when the wait happens, and the reject recorded at knockout - all against the same heat.
Misrun rate read against pouring temperature and against wait time, so the relationship is visible instead of assumed.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Two ladles went in well below the run. Both carry a delay reason logged at the time.
Tagged by the operator as it happened, not reconstructed afterwards.
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
Sand-defect rejects and box turnaround, by shift and pattern.
Rework hours and consumable burn per casting.
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.