Cut product changeover time and startup material losses.
Andvora helps production teams log changeover stages, isolate root causes of delays, and quantify scrap before stable production resumes.
Public demo runs on simulated shift data. Zero physical machine connection required.
Root Operational Bottlenecks
Three cost-leakage points during product changeovers
Many extrusion plants treat setup downtime as an inevitable fixed cost, even though most delays stem from lack of standard workflow enforcement.
Setup Logged as a Black Box
Shift reports aggregate "Setup 60m". Management never sees whether 20m was lost waiting for clamp bolts, die heating drift, or raw material delivery.
Startup Scrap Never Measured
Degraded purge lumps and off-gauge trial profiles are discarded into scrap bins without weight logging or attribution to specific job transitions.
The Same Bottlenecks Repeat
Without structured corrective actions assigning specific owners to deadlines, night shift setup technicians encounter the exact same tooling breakdowns.
5-Stage Closed-Loop Workflow
Prepare → Execute → Measure → Review → Improve
A closed-loop system enforcing external SMED readiness prior to line stop through post-run corrective action verification.
External Readiness
Verify target die, dried resin, color dosing, and QC calipers at the machine before stopping the line.
Setup Stages & Delays
Log duration per setup step (strip-down, purge, die mount, thermal soak). Tag specific delay causes in real time.
Scrap Weight & QC Gate
Weigh startup purge lumps and trial pipe. Enforce first-piece quality gate signoff before line ramps to run speed.
Loss Pareto & Handover
Analyze downtime Pareto rankings and export structured shift handover briefs without data disputes.
Corrective Action (CAPA)
Assign action items to maintenance leads with due dates and verified prevention signoffs.
Operational Deliverables
What plant teams receive for every logged changeover
Structured operational data ready for daily shift standups and quality compliance audits.
Planned vs Actual Time
Minute-by-minute duration deviation per setup stage with variance alerts.
Root Cause Categorization
Categorization into mechanical, electrical, resin, or procedural bottlenecks.
Kilograms of Purge & Off-Gauge
Total scrap weight in kg and estimated material cost when unit price is supplied.
QC Inspector Signoff
Certified approval of dimensional tolerances before lines resume production.
Assigned Owner & Due Date
Corrective action registry with two-step effectiveness verification.
Clean Shift Handover Export
Copyable handover brief and structured JSON export for daily production reports.
Intended Plant Roles
Built for practitioners accountable for line throughput
Plant / Operations Manager
Monitors cross-line loss Pareto rankings, evaluates setup consistency, and tracks startup scrap material costs.
Continuous Improvement Engineer
Standardizes SMED sequences, analyzes operator setup time variance, and validates CAPA effectiveness.
Shift Supervisor & Technician
Logs setup steps and delays in seconds via line-side tablet without retyping notes during shift handover.
Quality Control Inspector
Certifies first-piece dimensional tolerances before operators ramp the extruder to standard production speed.
Validate the workflow on 1 designated bottleneck line.
We offer a controlled plant pilot to verify that your shift technicians can adopt standard logging discipline and expose valid loss data.