PSI Terminology Glossary
Purpose: Comprehensive glossary of PSI-specific terms for AI agents and new team members. Understanding this vocabulary is critical for working with PSI data and systems.
How to Use This Glossary
AI agents should reference this document when encountering unfamiliar terms in PSI data or documentation. Terms are organized alphabetically with cross-references where helpful.
A
AFTEC
The core ERP database system (UniData) where all PSI business data lives. All PSI applications query AFTEC through the PSI Local Service. See Data Brain.
Assembly (ASSEMBLY)
A GTCode indicating an assembled component in the BOM hierarchy. Assemblies are built from multiple parts and may contain modules or physicals. See also: Module, PHYS.
Audit Type
A classification field in redbook tickets indicating the type of audit or review that identified the issue (e.g., “Mech”, “Elec”, “Customer”).
B
Blast Room
A large enclosure designed for abrasive blasting operations. One of PSI’s core product types. Blast rooms can be manual or automated. See Products & Services.
BOM (Bill of Materials)
Hierarchical list of all parts and assemblies that make up a machine. The BOM structure defines the parent-child relationships between components. Levels include FACILITY > ASSEMBLY > MODULE > PHYS.
BOM Level
The depth in the BOM hierarchy. Level 0 is the top-level assembly (machine), Level 1 is direct children, etc.
C
CAClass (Cost Accounting Class)
A part classification system used in job cost reports. Has ~88% coverage in the parts master. Different from MClass which is used by purchasing.
Calibration Factor
A multiplier applied to AI-estimated hours to align with actual observed values. Current calibration: shop hours at 0.87x, engineering at 1.0x.
Closer
The person who resolved/closed a redbook ticket. Note: In current data exports, the actual closer is often unavailable, so “closer” may default to the opener.
Controls Engineering
The electrical/software engineering department (Dept 111) responsible for PLC programming, electrical design, and automation systems.
Cost of Quality (COQ)
Total cost associated with quality issues including labor to fix, materials, rework, and customer impact. PSI targets <2% of project value.
CSS (Customer Support Services)
Department responsible for machine testing, runoff management, punch list resolution, customer training, and shipping coordination. CSS works primarily in the Develop, Demonstrate, and Deliver phases of the LDS methodology. See also quality.
D
Days Before Ship
The number of days between when a redbook was opened and when the project was scheduled to ship. Negative values indicate issues opened after the planned ship date.
Deep Dive
A detailed analysis of a specific subset of issues. In the dashboard, refers to the preventability analysis of top 100 Design Function issues.
Deployment Number
For products tracked in the design reuse system, indicates whether this is the 1st, 2nd, 3rd, etc. time a physical part has been used in a shipped project.
Design Function
A root cause category in the AI classification indicating the issue stems from the mechanical or controls design itself (undersized component, interference, missing feature, etc.).
Detection Timing
When in the project lifecycle an issue was discovered:
- Early (>90 days before ship): Found during design/early build
- Mid-Build (30-90 days): During main construction phase
- Late Build (<30 days): Crunch time before shipment
- Near/At Ship: Last-minute discoveries
- Post-Ship (Field): Found at customer site after shipment
E
ECN (Engineering Change Notice)
Formal document authorizing changes to engineering drawings or specifications. ECNs create audit trail for design modifications and are linked to affected parts. See Engineering Process.
Electrical Assembly
The assembly department (Dept 108) responsible for wiring, panel builds, and electrical installations.
Enrichment
The process of adding metadata fields to redbook records from other data sources (Project XML, user list, BOM data) without re-running AI classification.
Escape
A quality issue that “escapes” detection at one stage and is found at a later stage. “Field Escape” means the issue reached the customer site before being discovered.
Escape Rate
Percentage of total issues that are field escapes. PSI target: <3%.
F
Facility (FACILITY)
The highest GTCode level representing the complete machine or system. A facility contains all assemblies, modules, and physicals that make up the deliverable.
Field
Customer site where machines are installed and operated. “Field issues” or “field escapes” are problems discovered after shipment.
Field Service
The department (Dept 135) responsible for on-site installation, commissioning, and warranty support.
First-Time
In design reuse analysis, refers to the first deployment of a physical part. First-time deployments have statistically higher quality costs than reused designs.
FPY (First Pass Yield)
Industry standard quality metric. PSI adapts this concept as ”% of projects with no Major/Critical issues.”
G
GTCode (Group Technology Code)
Classification system for parts indicating their level in the design hierarchy:
- FACILITY: Complete machine/system
- ASSEMBLY: Multi-part assembled unit
- MODULE: Reusable functional unit
- PHYS.: Physical-level part (lowest reusable design unit)
- VM: Virtual/manufactured part
H
Has_ECN / Has_NCN
Boolean flags indicating whether a redbook ticket has an associated ECN or NCN.
Hours_* Fields
AI-estimated labor hours by department:
- Hours_Mech_Engineering
- Hours_Controls_Engineering
- Hours_Mech_Assembly
- Hours_Elec_Assembly
- Hours_Machine_Weld
- Hours_MVI
- Hours_Service
I
Industry
Customer industry classification (e.g., Aerospace, Automotive, Energy). Used for segmentation analysis.
Is_Retrofit
Boolean flag indicating whether the project is a retrofit (modification to existing machine) versus new build.
J
Job Number
Unique identifier for a manufacturing project. In PSI’s system:
- 4-digit numbers (e.g., 2374): New builds
- 5-digit numbers >=10000 (e.g., 12345): Retrofits
- “STOCK” or “0Stock”: Stock/inventory items
L
LDS (Logical Design Structure)
PSI’s foundational engineering methodology created by Lew VanKuiken in 1988. Organizes all engineering information around three pillars: Recordable, Re-usable, Retrievable. Defines six project phases (the “Six Ds”): Define, Design, Document, Develop, Demonstrate, Deliver. See lds-methodology for full documentation.
LDS Index
The master project organization document (file: xxxxlds.wk4) containing seven worksheets: Index (drawings/quantities), Job Summary (hours), Controls schedule, Mechanical schedule, GANTT Chart, Project Release form, and Macros. Created by Project Engineering using the SLDS Index as a starting reference. See Key Documents.
Labor Rate
Hourly cost used in quality cost calculations:
- Engineering rate: $150/hour (default)
- Shop rate: $125/hour (default)
Learning Curve
In design reuse analysis, the observed pattern that quality issues decrease as products mature through multiple deployments.
Long Tail Boost
A calibration adjustment (1.5x multiplier) applied to redbook tickets with base hours >4, accounting for the tendency of complex issues to require more time than AI estimates.
M
Machine Type
Classification of the type of machine being built (e.g., Blast Room, Spray Booth, Peen System). See Products & Services.
MClass (Manufacturing Class)
A part classification system used by purchasing/buyers. Has 100% coverage in the parts master.
Mechanical Assembly
The assembly department (Dept 106) responsible for mechanical installation, fitting, and assembly work.
Mechanical Engineering
The design engineering department (Dept 110) responsible for mechanical design, drawings, and specifications.
Module (MODULE)
A GTCode indicating a mid-level reusable functional unit. Modules are larger than individual physicals but smaller than full assemblies.
MRP Type
Material Requirements Planning classification:
- P: Purchased (bought from vendor)
- M: Manufactured (made in-house)
MVI
Machine Verification and Inspection department (Dept 120) responsible for quality checks, runoff testing, and verification.
N
NCN (Non-Conformance Notice)
Document for tracking quality issues with purchased parts or manufactured components that don’t meet specifications. Links to vendors, purchase orders, and dispositions. See Quality Process.
New Build
A brand new machine project (versus retrofit). Identified by 4-digit job numbers or 5-digit numbers <10000.
O
Opener
The person who created/opened a redbook ticket. Identified by employee ID in the raw data.
Opener_Dept
The department of the person who opened the redbook. Useful for understanding who is finding issues.
P
PAF Model
Prevention-Appraisal-Failure cost model from quality management. PSI’s current data captures mostly Failure costs.
PHYS. (Physical)
The lowest level GTCode representing a physical-level part. These are the fundamental reusable design units that can be deployed across multiple projects. The design reuse analysis focuses on PHYS. level parts.
Pipeline
The data processing sequence that transforms raw redbook exports into the analysis database. Includes data prep, AI classification, and enrichment stages.
Post-Ship
Issues discovered after the machine has shipped to the customer site. Also called “field escapes.”
Preventability
Assessment of whether an issue could have been prevented with better processes, reviews, or tools. The deep dive analysis found 94% of top Design Function issues were preventable.
Priority
The urgency level assigned to a redbook (e.g., “1-High”, “4-None”).
Process Type
Classification of the manufacturing process the machine performs (e.g., Blast, Spray, Peen).
Product (LDS Context)
In the LDS methodology, a “Product” has a specific technical meaning: a standardized, reusable building block that has been designed, built, and tested once, then stored in a database for re-use across projects. Products are NOT customer deliverables — they are internal components that form the foundation from which machines are quoted, designed, manufactured, and tested. See also Product Class.
Product Class
A categorization system for parts by their functional type (e.g., “Work Door”, “Cabinet Weldment”, “Spindle Positioning”). There are 345 product classes.
Product_Deployment_Count
The total number of projects in which a specific physical part has been used.
Project Value
The dollar value of a project from the ERP system. Used to calculate Quality % (Quality Cost / Project Value).
Proposal Engineering
The department (Dept 115) responsible for customer quotes, proposals, and technical sales support.
Q
Quality %
Quality Cost divided by Project Value. PSI target: <2%. Can be calculated as mean (weighted) or median across projects.
Quality Cost
Total estimated cost of a quality issue including labor, materials, and stage multipliers. AI-estimated values should be used directionally, not as precise figures.
Quality Risk Score
A 0-100 score assigned to products based on issue rate, project spread, and cost impact. Calculated in the part_quality_metrics table.
R
RAG (Retrieval-Augmented Generation)
AI architecture pattern where relevant documents are retrieved and provided as context to the language model. Used in advanced knowledge management systems.
RAC (Runoff Acceptance Criteria)
Document defining what the customer must accept during runoff testing. Uses V/D/M markers: V (Verify), D (Demonstrate), M (Measurement). Created by Project Engineering before machine startup. See Key Documents.
Recurring Escape
A quality issue pattern where the same product + root cause combination appears across multiple projects, indicating an unfixed design problem.
Redbook
PSI’s internal term for a quality issue ticket. When someone discovers a problem during design, build, or field installation, they open a redbook. The name comes from the original red physical notebook system. See Quality Process.
Resolution Days
The number of days between when a redbook was opened and when it was completed/closed.
Retrofit
A project that modifies or upgrades an existing machine rather than building new. Identified by 5-digit job numbers >=10000.
Reuse Rate
In design reuse analysis, the percentage of physical parts that have been deployed before (not first-time). PSI shows ~82% reuse rate at PHYS. level.
Root Cause
The fundamental reason why a quality issue occurred. AI-classified into categories like Design Function, Vendor Quality, Wiring Error, etc.
Runoff
Final testing and verification of a machine before shipment, typically with customer witness.
S
Six Ds
The six phases of the LDS methodology: Define, Design, Document, Develop, Demonstrate, Deliver. Every PSI project follows these phases from customer need to delivered solution. Documentation runs continuously through all phases.
SLDS (Sales LDS Index)
Preliminary product index created during the proposal/sales phase by Proposal Engineering. Used as the starting reference for the full LDS Index. The SLDS is a guide; the LDS Index is the authoritative project document. See Key Documents.
Severity
The impact level of a quality issue:
- Critical: Safety risk or major customer impact
- Major: Significant rework or schedule impact
- Moderate: Noticeable issue requiring correction
- Minor: Small issue with minimal impact
Ship_Date
The date a project shipped (or is planned to ship) to the customer.
Ship_Timing_Category
See Detection Timing.
Ship_Year
The year a project shipped, used for trend analysis and filtering.
SLA (Service Level Agreement)
Target resolution times by severity:
- Critical: ⇐3 days
- Major: ⇐14 days
- Moderate: ⇐21 days
- Minor: ⇐30 days
Stage Multiplier
A factor applied to quality costs based on when the issue was detected:
- Early (>90 days): 1.0x
- Mid-Build (30-90 days): 1.25x
- Late Build (<30 days): 1.5x
- Near/At Ship: 2.0x
- Post-Ship (Field): 2.0x
Stock
Parts or materials held in inventory rather than assigned to a specific project. Project number often shows as “STOCK” or “0Stock.”
Streamlit
Python web framework used for the dashboard application.
Systemic Issue
A root cause that appears across >50% of projects, indicating an organizational pattern rather than project-specific problem.
T
Task
A category of redbook entries that are to-do items or checklists rather than actual quality issues. Approximately 716 tickets are classified as Tasks and can be filtered out.
Thermal Spray
Surface coating process using heat and powder/wire materials. One of PSI’s core technologies. See Products & Services.
Timesheet
Labor time tracking records from the ERP system. Contains 2.76M records spanning 1992-2025.
U
Unique_ID
The primary key for redbook records in the database, combining ID and other fields to ensure uniqueness.
Userlist
The employee directory file (userlist.csv) containing employee IDs, names, departments, and initials.
V
Validator Mode
A feature in legacy dashboards (v4.28) for comparing AI classifications against human assessments.
Vendor Quality
A root cause category indicating the issue stems from purchased parts not meeting specifications.
VM (Virtual/Manufactured)
A GTCode for parts that are virtually defined or manufactured in-house.
W
WBS (Work Breakdown Structure)
Hierarchical numbering system for BOM items (e.g., 001, 00101, 0010101) showing parent-child relationships.
Where Used
ERP feature showing all jobs/assemblies where a specific part is used. Critical for design reuse tracking.
Wiring Error
A root cause category for issues related to electrical wiring mistakes.
Y
Yellow Book (Project Yellow Book)
Physical yellow binder containing all project documentation: Sales/Proposal section (customer RFQ, specs, quote, purchase order, SLDS Index, handoff notes), Engineering section (approved RAC, GANTT charts, floor layout), Customer Service section (test/process reports, shipping documents), and miscellaneous (post-project review, correspondence). Created by Proposal Engineering, passed to Project Engineering at handoff, filed in Library after project completion. See Key Documents.
Acronym Quick Reference
| Acronym | Full Term |
|---|---|
| BOM | Bill of Materials |
| CAClass | Cost Accounting Class |
| COQ | Cost of Quality |
| CSS | Customer Support Services |
| ECN | Engineering Change Notice |
| ERP | Enterprise Resource Planning |
| FPY | First Pass Yield |
| GTCode | Group Technology Code |
| LDS | Logical Design Structure |
| MClass | Manufacturing Class |
| MRP | Material Requirements Planning |
| MVI | Machine Verification and Inspection |
| NCN | Non-Conformance Notice |
| PAF | Prevention-Appraisal-Failure |
| PDM | Product Data Management |
| PHYS. | Physical (part level) |
| PSI | Progressive Surface Inc. |
| RAC | Runoff Acceptance Criteria |
| RAG | Retrieval-Augmented Generation |
| SLDS | Sales LDS Index |
| SLA | Service Level Agreement |
| VM | Virtual/Manufactured |
| WBS | Work Breakdown Structure |
Department Codes
| Code | Department |
|---|---|
| 100 | Maintenance |
| 101 | Administration |
| 102 | Machining |
| 104 | Welding |
| 106 | Mechanical Assembly |
| 108 | Electrical Assembly |
| 110 | Mechanical Engineering |
| 111 | Electrical/Controls Engineering |
| 115 | Proposal Engineering |
| 120 | MVI (Machine Verification & Inspection) |
| 125 | Process Services |
| 130 | Process Development |
| 135 | Customer/Field Service |
| 140 | Sales |
| 150 | Supply Chain |
| 160 | Materials Flow |
| 170 | Operations |
| 180 | Finance/HR/Admin |
Last updated: February 2026