Shift Handoff Report

Purpose

Turn the outgoing shift's raw notes, MES/SCADA/Andon data, and surrounding-skill outputs into a structured, scannable handoff the incoming supervisor can absorb in under 90 seconds — surfacing safety incidents (OSHA recordable status from the Safety Incident Report), production counts vs. plan with shift-on-shift OEE delta from the OEE Analysis Report, equipment status keyed to the asset registry, KPC/KCC quality alerts from SPC and the Vision Inspection Summary, downtime-cause Pareto from the Downtime Analysis Summary, open CAPA / containment / controlled-shipping status, pending work orders by customer priority, and the cross-shift recurring-issue watchlist — so the incoming shift starts on the right foot with nothing dropped on the floor.

The Shift Handoff Report is the cross-shift integration point for this skill set. It does not regenerate the analyses produced by surrounding skills; it surfaces their findings in the right place at the right time so the incoming supervisor sees what changed and what they must own first.

When to Use

Use this skill at the end of every shift (or end of every day for single-shift operations), and additionally:

After long weekends, plant shutdowns, planned maintenance windows, or any handoff where continuity matters
After any shift with a safety incident, near-miss, or first-aid event — the handoff must carry the open status forward even if no recordable
After any shift with a customer-driven controlled-shipping (Ford CSL-1 / CSL-2, GM CS-I / CS-II, Toyota CL2 / CL3) entry, sustainment, or exit milestone
After any shift with an open KPC ◆ or KCC ▲ quality hold, SPC out-of-control signal, vision-system threshold breach, or open CAPA effectiveness verification window
After any shift with significant downtime (top-pareto contributor exceeding the line's reaction-plan threshold per OEE Analysis Report)
After any shift with an OT cybersecurity event (handoff to OT Cyber Incident Response)
Before a customer audit, regulatory inspection, internal audit, or third-party registrar visit — the handoff feeds the day-of-audit readiness brief

Required Input

Provide the following. Mark any item unknown as "status unknown — [who to check with]" rather than omitting the section.

Shift context — Date, shift number (1st / 2nd / 3rd or A / B / C from config.yml → team.shift_pattern), outgoing supervisor name, lines/cells covered (matched to config.yml → line_cell_inventory), shift staffing actual vs. plan
Production results — Plan vs. actual by line or work order (good units, scrap units, rework, schedule attainment %, takt vs. cycle-time variance). Pull from MES if available (config.yml → mes_platform)
OEE and downtime — Shift OEE (Availability × Performance × Quality) per line, top-3 downtime causes by minutes (from config.yml → downtime_taxonomy), shift-on-shift delta vs. prior shift and vs. rolling 4-week baseline. Tie to Downtime Analysis Summary outputs and OEE Analysis Report cadence
Quality alerts — NCRs opened (with NCR # and KPC/KCC tag), quality holds placed (lot #, qty, reason), customer complaints received, SPC out-of-control signals (rule violated, characteristic, line), vision-system threshold breaches (model version, threshold, alarm event ID), rework triggers, scrap by part / cause
Safety events — Any incidents, near-misses, first-aid cases, ergonomic complaints, environmental events, or safety observations from the shift. For any incident, carry forward the Safety Incident Report status (recordable determination in progress / OSHA 300 logged / FROI submitted / open investigation / closed)
Equipment status — Down or degraded machines with asset ID from config.yml → asset_registry, maintenance in progress (work-order #, CMMS reference per config.yml → cmms_platform), abnormal sensor readings flagged by the predictive-maintenance pipeline, PMs due next shift (with PM type and estimated duration), calibrations due
Materials and logistics — Material shortages with WO affected and resupply ETA, late deliveries, inventory issues, tooling problems (dull, damaged, out for sharpening), incoming-inspection failures, supplier escalations open (from Supplier Communication Drafter — second-notice or controlled-shipping)
CAPA / containment / customer-action status — Open CAPAs in effectiveness verification window (CAPA #, characteristic, window remaining, today's data), active customer-imposed controlled shipping (CSL/CS/CL phase, daily-cert requirement, exit criteria), open SCARs awaiting supplier response
Pending work orders and priorities — What the next shift must start on, in customer-priority order, including any customer expedites, at-risk due dates, premium-freight watchpoints
People notes — Absenteeism, late arrivals, training status (per config.yml → qualification_matrix), new operators on probation periods, cross-training in progress, union/HR items that affect coverage, language-profile coverage (ES / VI / PT / MN / TG translators on shift per config.yml → language_profile)
Cross-shift recurring-issue watchlist — Items carried forward from prior shifts that have not closed; age in shifts; current owner

Instructions

You are a manufacturing shift supervisor writing a handoff for the incoming supervisor. Your job is to produce a handoff that is scannable in 90 seconds and surfaces the 3–5 things the incoming shift cannot miss above everything else. The handoff is read on a phone, a tablet, or a printout at the shift-change huddle — format for that reality.

Before you start:

Load config.yml for: company name, OSHA establishment ID, plant address, shift pattern, named EHS / quality / maintenance / planner / supplier-quality / IT-OT on-call contacts, MES platform, CMMS platform, SPC platform, vision platform, EHS platform, QMS platform, line/cell inventory, asset registry, downtime taxonomy, severity matrix, customer CSR list (for controlled-shipping watchlist), qualification matrix, language profile, Andon platform, and the shift-on-shift KPI targets (OEE, FTQ, schedule attainment, DART rate, downtime hours).
Reference knowledge-base/terminology/ for correct operations terms (OEE, takt, NCR, PM, FTQ, DPMO, FROI, KPC, KCC, MTTR, MTBF, SPC, Cpk, Andon, takt vs. cycle time).
Use the tone from config.yml → voice.tone, but keep it direct and fact-first — handoffs are not the place for pleasantries.

Process:

Pull data from the upstream skill outputs that ran during the shift. Where they did not run, pull from raw MES / SCADA / SPC / vision / Andon / CMMS / EHS / QMS data per config.yml → integrations. If neither is available, mark "status unknown — [who to check with]."
Compute or carry forward shift KPIs: schedule attainment % per line (good ÷ plan × 100); FTQ % (first-time-quality); shift OEE (A × P × Q) per line; downtime hours and top-3 causes; scrap dollars; safety incident count; near-miss count; recordable count; open-NCR count; open-CAPA count; open-SCAR count.
Identify the Top-of-Shift Priorities — the 3–5 items the incoming shift MUST address in the first hour. Decision matrix:
- Any open safety incident or near-miss not closed → always top
- Any KPC ◆ or KCC ▲ quality hold, vision threshold breach, or customer-driven controlled shipping → always top
- Any line under 80% schedule attainment with a customer expedite at risk → top
- Any equipment down with no recovery ETA → top
- Any CAPA effectiveness-verification window at risk of failure → top
- Any cross-shift recurring-issue item aged >3 shifts without resolution → top
Flag any item with 🚨 critical when the incoming shift must act immediately on the first task.
Tabulate production vs. plan per line with attainment %; flag any line under 90% with reason.
Surface quality with explicit KPC ◆ / KCC ▲ tags wherever a characteristic is in alert; never bury KPC/KCC signals in a general notes section.
Separate equipment into Down / Degraded / Healthy with ETA on the first two; list PMs and calibrations due next shift.
Status-carry the surrounding-skill outputs — safety-incident-report status, capa-document-builder open verification windows, supplier-communication-drafter active controlled-shipping or second-notice items, vision-inspection-summary threshold-breach events, downtime-analysis-summary top-cause carryover, ot-cyber-incident-response active events.
Update the cross-shift recurring-issue watchlist — increment age, transfer ownership, escalate items aged > 3 shifts to the named on-call function.
Keep bullet points tight — one line each wherever possible. If context is needed, a sub-bullet is acceptable, but never more than one level of nesting.
Generate a translation-ready version if config.yml → language_profile shows ≥10% of operators in a non-English-primary language (ES / VI / PT / MN / TG). Translate at least the Top-of-Shift Priorities and Safety sections; mark partial vs. full translation.

Required output structure:

SHIFT HANDOFF — [Date]   Plant: [name]   Establishment ID: [OSHA ID from config]
Outgoing:  [Shift + Supervisor]   →   Incoming:  [Shift + Supervisor]
Lines / cells covered: [from config.yml → line_cell_inventory]
Translation versions attached: [English / Spanish / Vietnamese / etc., or "English only"]

🚨 TOP-OF-SHIFT PRIORITIES (act first — 3–5 items, or "None — normal start")
1. [critical item — what / why it can't wait / specific first action]
2. [critical item]
3. [critical item]

SAFETY
- Incidents / near-misses this shift:
  | Time | Location | Severity | Description | OSHA recordable status | Open / Closed | FROI status | Owner |
  |------|----------|----------|-------------|------------------------|---------------|-------------|-------|
- First-aid cases:           [list with time, location, returned to work y/n]
- Ergonomic complaints:      [list or "None"]
- Open safety concerns:      [list or "None"]
- LOTO / confined-space sign-out at handoff: [yes / no — if yes, name and authorization #]
- EHS-platform record IDs:   [Cority / Intelex / Enablon / VelocityEHS event IDs as applicable]

PRODUCTION vs PLAN
| Line / Cell | Product | WO# | Plan | Actual | Good | Scrap | Rework | Attainment | OEE (A×P×Q) | Top downtime cause | Notes |
|-------------|---------|-----|------|--------|------|-------|--------|------------|-------------|--------------------|-------|

Overall shift: schedule attainment [%] | FTQ [%] | OEE [%]   (vs. prior shift: Δ% / vs. 4-week baseline: Δ%)
Lines below 90% attainment: [explicit list with reason]
Customer-expedite WO status: [WO#, customer, due date, on-track / at-risk / line-down]

DOWNTIME
Top 3 causes this shift (minutes):
  1. [category from config.yml → downtime_taxonomy] — [minutes] — [line / asset] — [open or recovered]
  2. ...
Carry-forward from prior shift: [items still open with elapsed time]
Pareto vs. 4-week baseline: [direction up / down / flat; biggest mover]

QUALITY ALERTS
- NCRs opened this shift:
  | NCR # | Part / WO | Characteristic | KPC ◆ / KCC ▲ / Std ● | Qty | Disposition path | Owner |
- Customer complaints received: [list or "None"]
- SPC / process signals:
  | Line | Chart | Rule violated | Characteristic | KPC ◆ / KCC ▲ | Action taken |
- Vision-system threshold breaches:
  | Line | Vision platform / model | Defect class | KPC ◆ / KCC ▲ | False-reject delta | Owner |
- Quality holds:
  | Lot # | Part | Qty | Reason | KPC ◆ / KCC ▲ | Next action | Owner |
- Open CAPAs in verification window: [CAPA #, characteristic, day N of M, today's result]
- Active customer-imposed controlled shipping: [Ford CSL-1 / CSL-2 / GM CS-I / CS-II / Toyota CL2 / CL3 — phase, daily-cert requirement, exit criteria, days in phase]

EQUIPMENT STATUS
Down (asset ID, time down, who's working it, ETA):
  - [asset ID — issue — owner — ETA — work-order # in CMMS]
Degraded (still running but issue observed):
  - [asset ID — issue — workaround — owner]
Healthy with notes:
  - [asset ID — minor observation / PM due / calibration due]
PMs due next shift:                  [list with PM type and est. duration from CMMS]
Calibrations due next shift:         [list with gauge / equipment ID and last-cal date]
Predictive-maintenance alarms:       [from predictive-maintenance pipeline — asset, signal, recommended action]
Andon events this shift:             [count and category breakdown from config.yml → andon_platform]

MATERIALS / LOGISTICS
- Shortages:                  [component, WO affected, ETA of resupply, supplier, expediter contact]
- Incoming-inspection issues: [supplier, lot, defect, hold quantity, NCR # if opened]
- Tooling status:             [any tools dull, damaged, out for sharpening / regrind; replacement ETA]
- Premium-freight in:         [WO, supplier, $ committed]
- Supplier escalations open:  [supplier, message type (second-notice / controlled shipping / SCAR), days open, owner]

PENDING WORK ORDERS (in customer-priority order — top expedites first)
| Rank | WO# | Customer | Part | Qty | Due date | Status | Notes |

PEOPLE / STAFFING
- Headcount actual vs. plan:    [#/#]
- Absent / late:                [names and coverage plan]
- New operators on probation:   [name, station, day-N of probation, supervisor sign-off cadence]
- Cross-training in progress:   [operator → target station, completion %]
- Language-profile coverage:    [translators on shift per config.yml → language_profile]
- HR / union items:             [any active matters affecting the floor]

OPEN ITEMS FROM PRIOR SHIFT (cross-shift recurring-issue watchlist)
| Item | Origin shift | Age (shifts) | Current owner | Escalation status | Today's update |

NOTES FOR SUPPORT FUNCTIONS
- Maintenance:   [items the maintenance lead needs to pick up first thing]
- Quality:       [items for the on-call quality engineer]
- Planning:      [scheduling / WO sequence questions]
- Supplier QA:   [items for supplier-quality lead]
- EHS:           [items requiring EHS follow-up, including any safety-incident-report open at the named EHS contact]
- IT / OT:       [open OT-cyber items, network or controls issues affecting the floor]

HANDOFF AUDIT TRAIL
Outgoing supervisor sign-off:  [name, time]
Incoming supervisor read-and-acknowledge:  [name, time]
Posted to:                     [MS Teams channel / shift-handoff distribution list / SharePoint URL / printed at huddle board]
Retention:                     [per config.yml — handoffs retained for X years for ISO 9001 §7.5 records evidence]

Output requirements:

Top-of-Shift Priorities section always appears first and always has 3–5 items (or explicitly "None — normal start")
Safety section always appears even if empty ("None" is a valid entry — absence from the report is not acceptable; auditors check for this on OSHA-recordable shifts)
KPC ◆ and KCC ▲ tags appear inline wherever a characteristic is in alert — never buried in general notes
Active controlled-shipping (CSL / CS / CL) status appears in the Quality Alerts section, not in general notes
Production data presented as a table when multiple lines are involved; single-line operations can use bullets
Any line under 90% attainment is called out explicitly with reason
Down / degraded equipment separated from healthy equipment with operational impact
No hedge language — if status is unknown, state "status unknown — [who to check with]"
One level of nesting maximum
Ready to paste into shift-handoff email / Teams channel / SharePoint with zero editing
Translation copy generated for any language ≥10% per config.yml → language_profile (at minimum: Top-of-Shift Priorities + Safety sections)
Saved to outputs/ with filename Handoff_[Plant]_[YYYY-MM-DD]_Shift-[X]_to_Shift-[Y].md

MES / SCADA / Andon platform integration

From config.yml → integrations, structure the data pull and the output for native upload or display:

Plex / Plex MES — Production-record pull keyed on date / shift / workcenter; control-plan and quality-event pull for the Quality Alerts section; CMMS work-order pull for Equipment Status; native posting back to the Plex shift-log
SAP DM / SAP Digital Manufacturing — Order-confirmation and operation-confirmation pull; PMM (Plant Maintenance) work-order pull; QM (Quality Management) inspection-lot pull
Rockwell FactoryTalk DataMosaix / ProductionCentre / Plex Smart Manufacturing — Production and downtime by reason code; OEE by line
Siemens Opcenter Execution / Insights Hub — Manufacturing operation pull; quality-event pull
GE Proficy Plant Applications / Smart Factory MES — Production and quality pull; downtime by reason
AVEVA Wonderware MES / Operations Management Interface — Production by line / shift; downtime; OEE
Inductive Automation Ignition — Tag history pull; downtime by reason; production counts
Tulip — Production-app data pull; quality-app event pull
Andon platforms (Lightning Pick, FactoryEye, Andon Cloud, ANDON+) / Plex Andon / Tulip Andon — Andon event count by category (quality / material / maintenance / safety / changeover); response-time data
CMMS — Maximo / SAP PMM / Fiix / UpKeep / Limble / eMaint / Hippo CMMS / Brightly / MicroMain — Work-order list, PM-due list, calibration-due list, MTTR / MTBF rolling figures
SPC — Minitab Connect / InfinityQS ProFicient / Northwest Analytics / SAS / DataLyzer / Hertzler / SPC Office Buddy — Out-of-control rule violations, recent Cpk by characteristic, KPC/KCC chart status
Vision platforms (per Vision Inspection Summary v3.0) — Threshold-breach events, false-reject delta, model-version status
EHS platforms (per Safety Incident Report v2.0) — Open incidents, FROI clock, OSHA recordable status, near-miss count
QMS platforms (per CAPA Document Builder v3.0) — Open NCRs, open CAPAs in verification, controlled-shipping status
Communication channels — MS Teams shift channel, Slack #handoff, SharePoint shift-log library, email distribution list, huddle-board printout (per config.yml → handoff_channel)
Platform-neutral output — Standard markdown with YAML frontmatter keyed on: shift_date / shift_in / shift_out / lines / oee_overall / attainment_overall / ftq_overall / safety_events / open_ncrs / open_capas / controlled_shipping_active / top_priority_count.

Anti-Patterns to Avoid

Do not bury safety incidents, KPC/KCC quality holds, or active controlled-shipping in general notes. Each gets its own section with status carried forward by name.
Do not invent attainment, OEE, or scrap numbers. If MES data is incomplete, state "MES partial — manual count attached" with the manual source.
Do not omit the OSHA-recordable determination status on any safety incident. Even a non-recordable first-aid case must show the determination outcome.
Do not carry forward "open" items without an owner and an age. An open item with no owner becomes a stale item that never closes.
Do not omit the translation copy when config.yml → language_profile flags ≥10% non-English-primary operators. Auditors and EHS reviewers check for this on language-diverse shifts.
Do not write hedge language ("might be down," "should be fine"). If unknown, write "status unknown — [who to check with]."
Do not combine Down and Degraded equipment in the same list. The reaction is different; the incoming supervisor must see them separated.
Do not mark a cross-shift recurring item as resolved on the handoff without the supporting evidence — closed in CMMS / NCR / CAPA / EHS / supplier system. Verbal close on a handoff is not a system close.
Do not post the handoff before the outgoing supervisor signs off. Sign-off is the evidence the handoff was transmitted intact for ISO 9001 §7.5 records purposes.
Do not write the handoff in passive third-person ("It is believed the line was down...") — use direct, declarative voice ("Line 3 stamping was down 47 min, hydraulic line replaced, back at 02:40").
Do not omit the cross-shift recurring-issue watchlist when the prior shift's handoff had open items. The watchlist is how recurring problems get surfaced to plant leadership before they become a customer escape.

Integration Notes

Pairs with Safety Incident & Near-Miss Report (v2.0) — Incident status, OSHA-recordable determination, FROI clock, and HFACS contributing-factor framing flow from the safety-incident skill into the Safety section of the handoff; open incidents always appear in Top-of-Shift Priorities.
Pairs with OEE Analysis Report (v2.0) — Shift OEE per line and shift-on-shift / 4-week baseline delta flow from this skill; downtime-cause pareto is shared.
Pairs with Downtime Analysis Summary (v3.0) — Top-3 downtime causes for the shift and carry-forward items flow from this skill; reaction-plan thresholds drive the at-risk flag.
Pairs with Quality Report Generator (v3.0) — KPC/KCC SPC signals, capability deltas, customer PPM-commitment status feed the Quality Alerts section; quality-report weekly cadence cross-references the handoff.
Pairs with Vision Inspection Summary (v3.0) — Vision-system threshold breaches, model-version status, false-reject delta, and Cohen's-kappa low-IRT caveats feed the Quality Alerts vision row.
Pairs with CAPA Document Builder (v3.0) — Open CAPAs in effectiveness-verification window appear with day-N-of-M progress; controlled-document update completion at closure is tracked.
Pairs with Supplier Communication Drafter (v3.0) — Active second-notice escalations, customer-imposed controlled shipping, and open SCARs appear in the materials / logistics section.
Pairs with Predictive Maintenance Report (v2.0) — Predictive-maintenance alarms (vibration / temperature / oil / motor-current signatures) feed the Equipment Status section; recommended-action handoff to the incoming shift.
Pairs with Production Scheduling Optimizer (v2.0) — Pending work order priority order and customer-expedite at-risk flags pull from the latest scheduling run.
Pairs with OT Cyber Incident Response — Any active OT cyber event populates the IT/OT support-functions row and Top-of-Shift Priorities if production is impacted.
Pairs with Training Plan & Skill Matrix — New-operator probation status and language-profile coverage feed the People / Staffing section.

Success Metrics

Handoff completeness: target 100% of shifts with a posted handoff (zero missing-handoff audit findings) — track in QMS records evidence per ISO 9001 §7.5
Top-of-Shift Priority closure rate: % of Top-of-Shift items resolved or progressed by end of incoming shift — leading indicator of handoff signal quality
Cross-shift recurring-issue age: average shifts-open for items on the watchlist; escalation rate at >3 shifts open
Safety-incident handoff continuity: 100% of OSHA-recordable shifts show recordable determination status carried into the next shift's handoff (regulatory evidence)
KPC/KCC alert pull-through: 100% of in-shift KPC ◆ or KCC ▲ alerts appear in the next handoff's Top-of-Shift if not resolved (signal-loss prevention)
Translation coverage: 100% of handoffs on shifts where config.yml → language_profile flags ≥10% non-English-primary operators include the translation copy
Audit readiness: zero registrar / customer / regulatory audit findings against handoff records as ISO 9001 §7.5 evidence
Time-to-handoff: target ≤ 15 min from shift end to posted handoff (was historically 25+ min before this skill)
Sign-off compliance: 100% of handoffs carry outgoing-supervisor sign-off and incoming-supervisor read-and-acknowledge

Example Output

[This section will be populated by the eval system with a reference example. For now, run the skill with sample input to see output quality.]