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From molten metal to machined part; get full visibility across casting and machining operations.
Leanworx helps pressure die casting manufacturers reduce changeover delays, cut rejections, and sync downstream machining in real time.
Minimize Defects, Maximize Uptime
In pressure die casting, uptime and die health directly impact throughput. Add to that downstream machining delays and quality challenges like porosity and air entrapment, and you get a process where every minute and every defect matters. Leanworx monitors it all in real-time, helping you minimize defects and maximize machine availability so that every cast counts toward your bottom line.
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Log setup durations and flag delays due to die prep, tool shortages, or changeover inefficiencies.
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Correlate rejections with individual dies, operators, and shifts to pinpoint quality issues.
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Measure downtime caused by die wear, cooling problems, and unexpected breakdowns.
Track Die Health and Efficiency
Leanworx gives you real-time tracking across your casting cells and machining sections, so you can reduce rejections, shorten changeovers, and improve coordination across processes.
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Plan proactive replacements with wear trend reports and maintenance performance metrics.
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Push alerts to align casting output with downstream machining availability and avoid idle time.
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Uncover links between setup processes and quality loss to improve part yield.
Purpose-built for casting shops with machining lines, handling batches from 100 to 5,000 parts.
Die casting shops often see lower OEE than machining due to extended setup time and frequent tool maintenance.
Unplanned downtime during production shifts can slash output by as much as one-fifth.
Manual reporting gaps in cycle times and defects mask significant productivity drops
Air entrapment, porosity, and die wear cause most rejections — issues that better monitoring can help eliminate.
Precision Tracking for High-Stakes Production
Track die changeover times and identify high-delay setups
Monitor real-time cycle times to detect cooling or injection anomalies early
Correlate rejections to die wear and setup conditions for better preventive action
Use alerts to sync casting and machining and avoid WIP pileups or idle time
Run MTTA, MTTR, MTBF reports for maintenance planning and die replacement
Reduce porosity and rework through targeted quality reports linked to actual machine behavior
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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