Incident Management

Incidents in PROD-SYS track problems, deviations, and events that impact production quality, equipment performance, or personnel safety. They ensure accountability and enable continuous improvement through root cause analysis.

Understanding Incidents

An incident represents any unplanned event during production:

Equipment failures or malfunctions
Quality deviations or defects
Safety events or near-misses
Material issues or shortages
Process parameter excursions
Operator errors or training gaps

Incident Lifecycle

Abierto → En investigación → Cerrado

Abierto: Newly reported, awaiting investigation
En investigación: Root cause analysis in progress
Cerrado: Resolved with corrective action documented

Creating an Incident

Navigate to Producción → Incidentes.

Access Incident Form

On the incidents page, find the “Reportar Nuevo Incidente” card on the left.

Enter Short Title

Provide a concise description (e.g., “Motor bearing failure on T-03”).Good titles:

“Broken needle on sewing machine #5”
“Ancho parameter out of spec”
“Material shortage - polymer batch delayed”

Avoid vague titles:

“Problem”
“Machine stopped”
“Issue”

Select Severity

Choose the impact level:Baja (Low - Informational)

No production impact
Minor observations
Process improvement opportunities

Media (Medium - Deviation)

Quality parameter deviation
Reduced efficiency or throughput
Workaround implemented
Scheduled maintenance required

Alta (High - Line Stoppage)

Production line stopped
Critical quality failure
Safety hazard present
Major equipment damage

Describe the Problem

Enter a detailed description including:

What happened
When it was detected
Which machine/process/order affected
Immediate impact on production
Initial observations

Example:

Durante el turno T2 (15:30), se detectó vibración anormal en motor
principal de telar T-03 durante producción de orden 2000145. 
Temperatura del motor aumentó de 60°C a 85°C en 10 minutos.
Operador detuvo máquina preventivamente. 
Producción aproximada perdida: 200 m².

Link to Execution (Optional)

If the incident is associated with a specific production line:

The system can link to linea_ejecucion_id
This connects the incident to the order + process + machine context

Currently, línea selection is not exposed in the UI. Future versions will support dropdown selection.

Click Registrar Incidente. The incident is created with:

Estado: “abierto”
Fecha_creacion: Current timestamp
Auto-assigned incident ID

Incident List View

The incidents table shows:

Column	Description
Fecha	Creation timestamp
Incidente	Title (short description)
Severidad	Baja, Media, Alta with color badge
Estado	abierto, en_investigacion, cerrado
Acciones	Update status or view details

Sorting and Filtering

Incidents are displayed:

Sorted by creation date (newest first)
Color-coded by severity:
- 🟢 Green: Baja
- 🟡 Yellow: Media
- 🔴 Red: Alta

Updating an Incident

Select Incident

Click on the incident row or “Acciones” button in the table.

Update Status

Change estado:

abierto → en_investigacion: Investigation started
en_investigacion → cerrado: Resolution complete
abierto → cerrado: Quick resolution (minor issues)

Document Corrective Action (for Closure)

If closing the incident, the accion_correctiva field is required:Include:

Root cause identified
Corrective action taken
Preventive measures implemented
Verification of effectiveness

Example:

Causa raíz: Rodamiento del motor desgastado (>5000 horas de uso).
Acción correctiva: Reemplazo de rodamiento 6308-2RS.
Mantenimiento preventivo: Programado cada 3000 horas operativas.
Verificación: Motor funcionando normalmente, temperatura estable 55-60°C.
Producción reanudada a las 18:45.

Save Changes

Update the incident record. The system:

Sets fecha_cierre (timestamp) when estado becomes “cerrado”
Validates that accion_correctiva is provided for closed incidents
Logs the update in audit trail

Inline Incident Reporting

During Shift Log Recording

For Proceso 1 (Extrusor PP), incidents can be logged directly in the process data form:

Open Process Detail

From Bitácora de Turno, click on “Extrusor PP” process card.

Find Incidents Section

Scroll to the “Incidentes” section in the form.

Add Incident Details

Enter incident information inline. This is stored in the parametros JSON field of the registro_trabajo.

Save Process Data

The incident data is saved with the production record and can be extracted for formal incident tracking.

Inline incident reporting is currently specific to Extrusor PP. Other processes should use the dedicated Incidentes module.

Severity Guidelines

When to Use “Baja”

Process observations for improvement
Minor cosmetic defects (not affecting function)
Informational notes for management
Completed preventive maintenance
Training opportunities identified

When to Use “Media”

Quality parameter slightly outside tolerance
Equipment running with reduced capacity
Material substitution required
Rework needed (but production continues)
Delayed maintenance becoming urgent

When to Use “Alta”

Production line stopped or unable to operate
Quality failure requiring product hold or scrap
Safety incident or hazard requiring immediate action
Equipment failure with no immediate workaround
Customer complaint or shipment rejection

Always escalate safety incidents immediately to supervision, regardless of production impact.

Integration with Shift Logs

Impact on Closure

Incidents affect shift log closure:

Quality rejections in muestras trigger “Revisión” status
The _checkNeedsRevision() method detects incidents
Supervisor must review and approve closure
Observations become mandatory when incidents exist

Linking Context

Incidents linked to linea_ejecucion_id carry full context:

Production order (codigo_orden)
Process (proceso_id, proceso_nombre)
Machine (maquina_id)
Shift (bitacora_id → turno, fecha_operativa)
Operator (usuario from registro_trabajo)

This enables powerful root cause analysis by correlating:

Order specifications vs. actual parameters
Machine performance history
Operator training records
Material batch traceability

Incident Repository

The data model (from incidente.repository.js):

{
  id: 1,
  titulo: "Broken needle on machine 5",
  descripcion: "Detailed problem description...",
  severidad: "media",
  estado: "abierto",
  linea_ejecucion_id: 123,  // Optional link
  accion_correctiva: null,   // Required for closure
  fecha_creacion: "2024-01-25T14:30:00Z",
  fecha_cierre: null         // Set when estado = cerrado
}

Query Patterns

All incidents (newest first):

GET /api/incidentes

Create incident:

POST /api/incidentes
Body: { titulo, descripcion, severidad, linea_ejecucion_id }

Update incident:

PUT /api/incidentes/:id
Body: { titulo, descripcion, severidad, estado, accion_correctiva }

Best Practices

Report incidents immediately when detected, not at shift end

Use descriptive titles that allow quick incident identification

Include quantitative data in descriptions (temperatures, pressures, counts)

Link incidents to execution context when possible

Document corrective actions thoroughly for knowledge sharing

Use severidad consistently to enable trend analysis

Do not close incidents without documenting corrective action. This breaks continuous improvement.

Reporting and Analysis

Incidents support several analytical workflows:

Frequency Analysis

Group by severidad to identify high-impact areas
Count by proceso_id to find problematic processes
Trend over time to measure improvement initiatives

Pareto Analysis

Identify top causes (from descriptions or future categorization)
Focus corrective actions on high-frequency issues
Calculate downtime cost by severity

Root Cause Trends

Extract common themes from accion_correctiva text
Link to machine maintenance schedules
Correlate with material batch quality

Closure Time Metrics

Calculate fecha_cierre - fecha_creacion
Track average resolution time by severidad
Identify bottlenecks in investigation workflow

Audit Trail

All incident operations are logged:

CREATE: Initial report with username and timestamp
UPDATE: Changes to any field (status, description, corrective action)
CLOSURE: Final estado change with accion_correctiva

Access via Administración → Auditoría, entity type “Incidente”.

Future Enhancements

Planned improvements to incident management:

Categorization: Predefined incident types (mechanical, quality, material, operator)
Línea Selection UI: Dropdown to select execution line during incident creation
Attachment Support: Photos, documents, or logs associated with incidents
Notification System: Alert supervisors for alta severity incidents
Incident Board: Kanban-style view for tracking investigation progress
RCA Template: Structured root cause analysis form (5 Whys, Fishbone)

Troubleshooting

Cannot Close Incident

Error: “Acción correctiva es obligatoria para cerrar incidente”

The accion_correctiva field is required when estado changes to “cerrado”
Provide detailed description of resolution
Include verification of effectiveness

Incident Not Showing in List

Check creation timestamp (list sorted newest first)
Verify incident was saved successfully
Refresh page to reload data
Check browser console for API errors

Cannot Link to Execution Line

Línea selection is not yet exposed in UI
Currently requires direct API call or database update
Future versions will support dropdown selection

Shift Logs - Recording incidents during shifts
Production Orders - Context for order-related incidents
Traceability - Following incidents through production chain

Get Started

Core Features

User Guides

Production Processes

Administration

Incident Management

Understanding Incidents

Incident Lifecycle

Creating an Incident

Incident List View

Sorting and Filtering

Updating an Incident

Inline Incident Reporting

During Shift Log Recording

Severity Guidelines

When to Use “Baja”

When to Use “Media”

When to Use “Alta”

Integration with Shift Logs

Impact on Closure

Linking Context

Incident Repository

Query Patterns

Best Practices

Reporting and Analysis

Frequency Analysis

Pareto Analysis

Root Cause Trends

Closure Time Metrics

Audit Trail

Future Enhancements

Troubleshooting

Cannot Close Incident

Incident Not Showing in List

Cannot Link to Execution Line

Build docs developers (and LLMs) love

Get Started

Core Features

User Guides

Production Processes

Administration

​Understanding Incidents

​Incident Lifecycle

​Creating an Incident

​Incident List View

​Sorting and Filtering

​Updating an Incident

​Inline Incident Reporting

​During Shift Log Recording

​Severity Guidelines

​When to Use “Baja”

​When to Use “Media”

​When to Use “Alta”

​Integration with Shift Logs

​Impact on Closure

​Linking Context

​Incident Repository

​Query Patterns

​Best Practices

​Reporting and Analysis

​Frequency Analysis

​Pareto Analysis

​Root Cause Trends

​Closure Time Metrics

​Audit Trail

​Future Enhancements

​Troubleshooting

​Cannot Close Incident

​Incident Not Showing in List

​Cannot Link to Execution Line

​Related Topics

Build docs developers (and LLMs) love

Understanding Incidents

Incident Lifecycle

Creating an Incident

Incident List View

Sorting and Filtering

Updating an Incident

Inline Incident Reporting

During Shift Log Recording

Severity Guidelines

When to Use “Baja”

When to Use “Media”

When to Use “Alta”

Integration with Shift Logs

Impact on Closure

Linking Context

Incident Repository

Query Patterns

Best Practices

Reporting and Analysis

Frequency Analysis

Pareto Analysis

Root Cause Trends

Closure Time Metrics

Audit Trail

Future Enhancements

Troubleshooting

Cannot Close Incident

Incident Not Showing in List

Cannot Link to Execution Line

Related Topics