The daily production sheet is paper
It is accurate at the machine and stale by the time it reaches anyone who decides something.
Home Industries Manufacturing and production software
ManufacturingManufacturing and production software
Work orders, output, material consumption and downtime against one plan.
KaizenSpark Tech builds manufacturing systems — work orders, production recording, material consumption, quality checks, downtime and plant reporting — for operations where the shop-floor daily sheet is filled in by hand and reconciled at month end.
What this page is. Described from the problems operators in this sector actually bring us, and from systems we have built for them. Clients are withheld under confidentiality, so what follows covers the problem, the solution and the capability rather than the customer. More of our work is on our solutions.
Who it is for
Does this sound like your operation?
A plant or workshop where production, stock and quality are recorded on paper or in separate spreadsheets, and the monthly reconciliation is somebody’s week.
What it looks like
Kaizen Manufacturing, the product behind this.
The same system, shown as it would be configured for this sector. An illustration, not a screenshot.
manufacturing.kaizensparktech.com/dashboard
Kaizen Manufacturing
DashboardWork ordersProductionQualityMaintenanceStoresReports
Shop floor entries,
not a daily sheet.
not a daily sheet.
Plant
Work orders, output and downtime against one plan
This monthKM
Work orders open264 behind plan
Output today1,840units
Downtime2.4hthis shift
Rejections1.8%against 2% limit
Output against plan
By week, last eight weeks
Behind plan
Largest gap first
| Item | Stage |
|---|---|
| WO-1182 · line 2 | hold |
| WO-1176 · line 1 | hold |
| WO-1190 · setup | wait |
| WO-1171 · closed | ok |
| WO-1168 · closed | ok |
Interface illustration, drawn with this site’s own design tokens. Sample figures, not a running system.
The problem
What usually brings someone to us.
01
02
Material consumption is inferred
Issued against produced is calculated at month end, so a yield problem is found weeks late.
03
Downtime is remembered, not recorded
The reasons are anecdotal, so the biggest cause is argued about rather than measured.
04
Rejections are counted but not traced
A reject rate exists, but not which batch, machine or shift produced it.
05
Plan against actual is a monthly exercise
By the time the gap is visible, the month is over.
06
Stores and production disagree
Two stock figures, reconciled by hand, both out of date.
What we build
What the system would cover.
01
Work orders
Planned against actual, with the gap visible during the shift rather than after it.
02
Production recording
Entered at the point of work, by the person doing it, on whatever device is practical.
03
Material consumption
Issue against output per work order, so yield is a number not an estimate.
04
Quality and rejections
Checks against the batch, machine and shift that produced them.
05
Downtime
Captured with a reason code, so the ranking is measured rather than debated.
06
Plant reporting
Output, yield, downtime and rejection read from operational records.
Integrations
What it would connect to.
Existing ERP or accounting systems for the financial side, weighing and counting hardware at the point of work, and your stores system where one already exists. Machine-level data capture depends entirely on what your equipment exposes, and is confirmed before it is scoped.
How a build runs
The same five stages, whatever the sector.
01
Trace
We follow the work as it runs today and write it down — where the hours go, where data is re-keyed, where errors enter.
02
Scope
Deliverables, integration points, phases and an explicit out-of-scope list, agreed in writing before any code exists.
03
Build
Working software in reviewable increments, with a running environment you can open at any point during the build.
04
Measure
Type checks, automated tests and a manual pass on the paths that matter.
05
Improve
Architecture notes and runbooks ship with the build, then we keep reading the numbers with you.
06
What comes as standard
Written scope, documented handover, and IP transferred to you on final payment. Not extras.
Questions
What people ask before commissioning this.
Can we capture data from the machines themselves?
Sometimes. It depends on the controller and what it exposes, and the honest answer for older equipment is often no. We check before promising it, because retrofitting is frequently more expensive than the software.
Will operators actually use it?
Only if entry takes seconds and happens where the work is. If it requires walking to an office it will quietly go back to paper, and that is a design problem, not a training one.
Can it work alongside our existing ERP?
Yes, and that is usually the right shape: the shop floor records the work, the ERP keeps the ledger.
What about traceability for audits?
Batch to despatch traceability is a defined requirement we scope explicitly, because retrofitting it afterwards means changing how records are keyed.
Related
Where to look next.
Start here
Describe the process that costs you most.
We will come back with a scope and a cost range — including if our view is that software is not the right lever.