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Precision that starts with process control.
Leanworx helps gear manufacturers reduce setup losses, improve part quality, and boost uptime across high-mix, low-volume operations.
Optimize Precision and Setup Times
Gear manufacturing demands tight tolerances, long setup times, and high operator skill, all while handling low batch quantities and frequent profile changes. It’s a balancing act where precision can’t be compromised and efficiency is king. Leanworx helps you track every setup and change seamlessly, giving your team the insights they need to reduce downtime and keep quality consistent—even when the jobs keep shifting.
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Track setup times and cycle durations for every gear profile and machine type in real time.
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Drill down into stoppage patterns to identify recurring issues and reduce unplanned downtime.
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Monitor rejections by machine, part, and operator to minimize rework and quality losses.
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Log shift-change delays and break-time losses to drive accountability and improve discipline.
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Review individual performance on quality, load, and setup times to enable training and reward programs.
Real-Time Monitoring for Gear Shops
Leanworx equips gear shops with real-time visibility across processes like turning, hobbing, shaving, grinding, and heat treatment , helping reduce rejections, shorten setups, and improve overall machine and operator performance.
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Generate long-term reports on Availability, Performance, and Quality to benchmark productivity.
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Auto-generate maintenance tickets and track MTTA, MTTR, and MTBF for timely interventions.
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Receive mobile/email notifications for breakdowns, spike in rework, or unexpected downtime.
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Show real-time OEE, downtime, and planned vs actual on Andon boards and operator terminals.
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Easily produce ISO 9001 and IATF 16949-compliant records for traceability and quality audits.
Purpose-built for small-batch, high-mix, precision part manufacturing.
Low-volume, high-precision production demands setup visibility , Leanworx delivers it in real time.
Frequent changeovers stretch non-cutting time. We track and shorten every setup.
Poor machine availability and mid-shift delays slash productivity. Leanworx helps recover it.
Process variations and operator errors lead to scrap. Our analytics surface the root causes fast.
Precision Tracking for High-Stakes Production
Reduce setup losses with per-profile setup reports and downtime drill-downs
Minimize rework by identifying root causes through rejection analytics
Improve operator performance using incentive-linked metrics and targeted training
Address shift-change delays and break overages with clear, daily feedback loops
Monitor sequential processes like hobbing → shaving → heat treatment with integrated insights
Maintain compliance effortlessly with structured reports for customer audits and quality standards
Our subscribers includes some of the most prominent names in the manufacturing industry. Hear firsthand from leaders who have experienced the transformative power of our solutions.
An Indian automotive parts manufacturer faced growing challenges in managing operator efficiency and retention. While the company employed over 300 operators and ran 130 CNC lathes and machining centers, there was no reliable way to assess individual performance or reward high productivity. All operators received fixed salaries regardless of skill, discipline, or contribution to output.
A leading exporter of precision-machined castings for railways and off-road vehicles was facing a 15% annual growth in orders. At first glance, the solution seemed obvious: purchase 18 new machines to meet the additional demand. However, this would have required a ₹5.6 crore capital investment that the management was keen to avoid unless absolutely necessary.
A Tier-2 automotive parts manufacturer was losing close to 3 hours of productive time every day due to untracked machine downtime during shift changes. Across 39 CNC machines running three 8-hour shifts, this added up to a 12% reduction in daily output.
In a bustling hydraulic pumps manufacturing plant, one persistent issue was silently draining productivity — each of the 8 HMCs in a specific bay was experiencing one hour of daily downtime, consistently logged as “Waiting for Tool.” With each machine carrying a cost of ₹1000 per hour, the total monthly loss was nearly ₹2,00,000 across those machines.
An aerospace components manufacturer operating 40 CNC machines across three 8-hour shifts faced a puzzling issue: despite running 24 hours a day, output remained far below expectations. Spindle run times, a critical indicator of productivity, averaged only 30%. Yet machines were booked around the clock.
A leading springs manufacturer was facing an invisible yet costly problem: the absence of accurate, real-time production quantity data. Without knowing how many parts were being produced during each shift, they frequently overproduced, leading to inventory build-up and rising holding costs. On other days, they underproduced, causing delivery delays and reactive scheduling.
Smarter Operations, Less Supervision.
Get real-time visibility into machine status, output, and utilization with zero manual reporting delays or guesswork, across every shift and cell.
Know what’s running, what’s lagging, and what’s stopped. Track performance and part flow as it happens across shifts and job types.
Capture every unplanned stop with automated alerts. Log accurate downtime reasons and send instant notifications to teams for faster response.
Monitor Availability, Performance, and Quality over time. Compare OEE across shifts, machines, and product types with no manual effort required.
Connect machines to the cloud for smarter decisions. Start collecting real-time data without disrupting existing tools or production workflows.
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Ready to Cut Rejections and Setup Time in Gear Manufacturing?
See for yourself how easy it is to move from guesswork to precision manufacturing.
