Scrap by machine, order and cause.
Recorded in kilograms, where it is made, not as a share of the month.
The production manager readsSimon G. / Manufacturing / Scrap tracking
Scrap tracking software for manufacturers.
Simon G. shows scrap in kilograms, by machine, order and cause, and what it did to the cost of each lot. Every week it is measured against a baseline fixed when you started.
On your own serverNo internet neededYour data shared with no one
This page shows a fictional packaging-film plant, from extrusion through printing to confection.
Does this sound like your plant?
Everyone knows the scrap figure. Nobody knows what it cost.
The number arrives at month end. By then the lot has shipped.
- One figure, once a month. It says how much. It does not say which machine, order or cause.
- Scrap is counted, not priced. The loss sits in the month's cost, not on the lot that made it.
- Regranulate disappears into stock. What could go back into the recipe is not kept apart.
- The plan ignores it. Changeovers and cold starts are assumed, so their scrap is too.
- Every improvement starts an argument. Without a baseline, nobody can prove what changed.
- The reason stays on the floor. It never reaches the person who can change the rule.
What it shows
Kilograms, then cost, then cause.
Scrap is recorded per order and machine. Each lot carries its planned cost and its actual, and the gap says where to look: the recipe, the machine, the shift.
Scrap, share of output
Fictional company.
The fall follows a changeover rule signed in week 39.
A result without a baseline proves nothing.
Cost per lot, against planEUR/kg
Lot 4466+16 %Scrap 9 %. Opens the record for extruder 2, night shift.
Lot 4458-A+6.4 %Energy.
Lot 4458-B−3.1 %
Lot 4461on plan
Fictional company.
From record to decision
A number you can act on, and prove.
Scrap sits beside the plan, the materials and the cost. The whole picture is on the manufacturing page.
01
02
Cost per lot, planned against actual.
Materials, measured energy, labour and consumables, before the month closes.
The production manager reads03
Regranulate in and out.
Kept apart with its own stock. The plan uses it where the recipe allows.
The planner signs04
Changeovers counted in the plan.
By colour, width and material, with their cost. Cold starts too.
The planner signs05
A rule with a name on it.
A changed rule comes to one person, with its evidence, and is recorded.
A named person signs06
A baseline fixed before anything changes.
The same figure, measured the same way, every week.
Management readsWhat we read, so you prepare nothing
We do the work.
- OrdersSales orders and schedule lines, or the order e-mails planners receive.
- Recipes and routingsBills of material, machine speeds, set-up times.
- Stock and movementsRaw, semi-finished and finished goods, blocked stock.
- Machine hours and energyThe daily readings you already keep.
What it does not do
Plainly.
- It does not control machines.It reads the reports from the floor.
- It does not run the quality lab.It reads inspection results and blocked stock.
- It does not post to the ERP.Nothing is written back.
Your data stays yours.On your server. Shared with no one, not even through a chatbot.
Deterministic. No internet needed.The same inputs give the same answer, traceable step by step.
No implementation budget.We read your data ourselves. There is no project to fund.
Questions a production manager asks first
Short answers.
Does it connect to our machines?
No. It reads the reports from the floor. It does not control machines, and it is not a manufacturing execution system (MES).
Does it replace our quality system?
No. It reads inspection results and blocked stock. It does not test anything.
How do we know the improvement is real?
The baseline is fixed when you start. The same figure is then measured the same way, every week.
Can it put a cost on scrap per lot?
Yes. Each lot carries its planned cost and its actual: materials, energy at the measured rate, labour and consumables. The gap says where to look.
What do we have to prepare?
Nothing. We take the exports ourselves, with your IT beside us for a few hours, and set Simon G. up for your plant. There is no implementation project and no budget line for one.
Where does our data go?
Nowhere. It runs on your own server with no internet connection, and your data is shared with no one: not other companies, not us, not a chatbot.
Start with one decision
Bring one decision your company takes badly or too late.
Thirty minutes with a founder. We go through how Simon G. would prepare it and say in writing whether it fits.
We give the fees in the first conversation. How the pilot works. Planning in a spreadsheet today? See the Excel alternative.