Read-only engagements
CodeWaves.Engineers who read shop-floor paper.
One week. Then you know what to fix first. We reconcile the records your plant already keeps and put a number on what they hide.
The call is free. Nothing to send, nothing to install. Fixed fee after.
A milling cutter cutting metal under a heavy flood of coolant.
01 · The week
Five days. None of them in your plant.
Downtime log · sample
+ 210 more rows, all read the same way
28 hrs/mo
All 214 rows, on Op 30. The machine that sets plant output.
01
Downtime log · 4 of 214 rows · invented plant
Every stoppage your shift sheets already logged, sorted to the machine that matters. Four rows shown here, 210 more like them.
Downtime log · sample
DateSh.OpReasonMin03 MarAOp 30tool change4005 MarBOp 50waiting material6514 MarAOp 30setup8027 MarCOp 30setup120+ 210 more rows, all read the same way
28 hrs/mo
All 214 rows, on Op 30. The machine that sets plant output.
02
One month · three of the plant's own records · invented plant
Three ledgers, one number they don't agree on. What's left over after the known losses is the hour nobody wrote down.
Reconciliation · one month
Units · shift sheets12,840Units · despatch book12,310Units · ERP postings12,955Op 30 hours · planned 528, running 431, stops 28runningrecorded stopsunexplained69 hrs
Planned, minus running, minus stops. Usually the largest number of the week.
03
Machine load · % of available hours · invented plant
Every operation loaded with your real product mix, not a textbook one. The busiest ratio is the constraint, whatever the queue in front of it looks like.
Load by operation · % of available hours
Op 10
SawOp 20
TurnOp 30
MillOp 40
DrillOp 50
GrindOp 60
WashEveryone pointed at Op 50. It had the queue. Op 30, in orange, set the output.
04
One view of the plant · this shift · invented plant
Losses, rejects, queue and setups, read off one shift and matched against your own targets.
This shift, at a glance
6.5 hrs
Lost on Op 30 this week (flagged)
2.8%
Rejects this week
41 hrs
Queued in front of Op 30 (flagged)
9 of 6
Setups on Op 30, own target (flagged)
38%
Of lost hours: tool change (flagged)
87%
Despatched on the day
One file. Opens in any browser. Yours to keep.
- Monday
Your records arrive.
One month, photographed or exported, exactly as they are. Read by one engineer.
- Tuesday
We reconcile it.
Three of your own records, one month, every difference in units and hours.
- Wed to Thu
We find what caps your output.
Every machine loaded with your real mix. The highest ratio is the constraint.
- Friday
You get the read.
What to fix first, what it is worth, and the file that shows it. Yours to keep.
02 · Where we work
Any plant that keeps records and does not quite trust them.
Auto components
Which machine really caps output.
Foundries
What a rejected casting really costs.
Packaging and bottling
What actually stops the line.
Process and chemicals
Where the batch hours go.
Pharma formulations
Changeover and cleaning, per batch.
Stand-in photographs, not clients.
Via Wikimedia Commons: CNC lathe by Whoisjohngalt (CC BY-SA 4.0), casting by Samson iron (CC BY-SA 4.0), conveyor by falco (CC0), fermenters by Drew Cuddy (CC BY-SA 2.0), blister line by Aditiaudi (CC BY-SA 4.0), milling footage by Amada44 (CC BY 3.0).
03 · Who we are
An engineering practice. Software by trade, shop floors by habit.
Sagar
Founder
The truth about a plant is in its registers. The engineer who reads yours is the one who replies, and stands behind every line.
Sagar is a full-stack engineer and AI enthusiast who loves solving complex problems. With expertise in machine learning and distributed systems, he drives CodeWaves' technical excellence and innovation.
A few weeks a quarter, one plant at a time. We say no to the ones we would do badly.
- Fixed fee, in writing, before Monday.
- Read-only, always. Copies of your records. Nothing on your network.
- You keep everything. Report, data, showcase, script.
- No predictions without history. Measure first.
04 · Start
What it costs you to find out.
Free
A twenty-minute call.
What you make, what you already record. We say which question to answer first, and whether a week is worth it.
Fixed fee
The week, remote.
Only then do records change hands: one month, copies only, deleted when you ask.
Only if records run out
Five days on site.
Instrumented, read-only, priced before anyone travels.
Start here
Twenty minutes. Nothing to send.
Tell us what you make and when suits. We reply in two working days, and will say if this is not for you.