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.

See how the week works

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

DateSh.OpReasonMin
03 MarAOp 30tool change40
05 MarBOp 50waiting material65
14 MarAOp 30setup80
27 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.

  1. 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.OpReasonMin
    03 MarAOp 30tool change40
    05 MarBOp 50waiting material65
    14 MarAOp 30setup80
    27 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.

  2. 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 sheets12,840
    Units · despatch book12,310
    Units · ERP postings12,955
    Op 30 hours · planned 528, running 431, stops 28
    runningrecorded stopsunexplained

    69 hrs

    Planned, minus running, minus stops. Usually the largest number of the week.

  3. 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

    46%
    Op 10
    Saw
    58%
    Op 20
    Turn
    94%
    Op 30
    Mill
    71%
    Op 40
    Drill
    62%
    Op 50
    Grind
    37%
    Op 60
    Wash

    Everyone pointed at Op 50. It had the queue. Op 30, in orange, set the output.

  4. 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.

  1. Monday

    Your records arrive.

    One month, photographed or exported, exactly as they are. Read by one engineer.

  2. Tuesday

    We reconcile it.

    Three of your own records, one month, every difference in units and hours.

  3. Wed to Thu

    We find what caps your output.

    Every machine loaded with your real mix. The highest ratio is the constraint.

  4. 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.

CNC lathe on a shop floor

Auto components

Which machine really caps output.

Molten metal poured from a ladle

Foundries

What a rejected casting really costs.

Roller conveyor in a factory

Packaging and bottling

What actually stops the line.

Stainless steel process vessels

Process and chemicals

Where the batch hours go.

Blister-pack line in a pharma plant

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

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.
More about us

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.

Write to

hello@codewaves.co
Send a message