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High-speed, continuous lines demand real-time clarity — Leanworx delivers it.
We help packaging manufacturers uncover hidden downtime, reduce line stoppages, and maximize throughput without costly investments.
No More Bottlenecks, Just Bottles
Packaging lines lose momentum fast, from label jams to carton runouts. Leanworx gives you real-time visibility into every station, so you can keep the line flowing and catch stoppages before they snowball. It’s like having eyes everywhere—making sure your packaging runs smooth, efficient, and profitable all shift long.
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Track uptime, downtime, and run speeds across key stations like fillers, cappers, labelers, and conveyors.
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Monitor usage of films, inks, and tapes to avoid mid-cycle shortages that can halt production.
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Get instant alerts on speed drops or inconsistencies, enabling supervisors to intervene before stoppages occur.
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Log start/stop activity by shift to identify and eliminate time lost to late starts or early stops.
From Shift Variance to Shift Consistency
Late starts, micro-delays, and inconsistent speeds across shifts cause silent losses. With Leanworx, every shift runs to plan- with alerts, dashboards, and reports that make performance unmistakably clear.
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Generate shift-wise output reports to measure actual performance against production plans.
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Run station-wise OEE reports to pinpoint underperforming equipment and prioritize process improvements.
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Trigger real-time alerts for unexpected events like rejections, machine halts, or prolonged idle time.
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Maintain detailed reports aligned with customer and regulatory audit requirements for transparency and traceability.
Every Minute Counts on the Line
That’s 30 to 40% of capacity left untapped. Leanworx improves visibility, speeds up diagnostics, and helps you close the gap.
Misfeeds, jams, and material issues kill momentum. Leanworx flags root causes fast so your team can take action before output dips.
Running out of labels or cartons mid-cycle derails schedules. Leanworx tracks consumable usage and helps avoid unexpected shortages.
Small delays often go unnoticed. Leanworx detects micro-efficiency drops in real time—keeping performance on track across shifts.
Precision Tracking for High-Stakes Production
Track micro-stoppages in fillers, cappers, and labelers before they cause line shutdowns
Monitor consumable inventory, so film or tape runs don’t halt production
Analyze shift transition inefficiencies with visual shift-change performance logs
Optimize line balancing by comparing throughput and speed across stations
Enable predictive maintenance through usage and downtime trend analysis
Prepare transparent audit logs for customers and quality regulators
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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