ReduceWaste Request a pilot

Measure any factory. Find where it loses money.

Open-source software that reads your plant, tells you which sensors to fit, watches every machine and ranks what to fix this week. It runs on your own hardware.

Request a pilot
Site overview for Larkfield Precision · Plant 1 (simulated). The alarm summary lists three active alarms, including a P1 alarm for the CNC-2 bottleneck. Under it sit the OEE tile for the plant, the CNC cell 1 and CNC cell 2 tiles with their OEE and cycles, and the OEE tile for CNC-2.

CNC cell 2 is holding the line back

CNC cell 2 is holding the line back

  • Apache-2.0 open source
  • Runs on-prem, air-gap ready
  • Read-only toward machines
  • 21 languages

At 07:06 it flagged a bottleneck. Here is how it knew.

  1. Step 1: Alarm

    The alarm summary raised a P1 at 07:06. On the floor plan the same finding sits on CNC cell 2, and the Outfeed conveyor beside it reads starved 98%.

    Floor plan cut to three machine boxes: CNC cell 1, CNC cell 2 with a red priority diamond, and the Outfeed conveyor reading starved 98%.

    CNC cell 2 is holding the line back

    Floor plan · CNC cell 2Step 1 of 5

    CNC cell 2 is holding the line back

  2. Step 2: Evidence

    Ask which machine costs the most. The reply names CNC cell 2, the line bottleneck for 97% of the last 30 minutes, and lists its readings as chips. Its 66% for conveyor-1 covers those 30 minutes. The alarm's 98% is the figure at 07:06.

    The Ask reply: a paragraph on what drives the CNC cell 2 loss, then an Evidence list of chips including Packing station pack count, oee cnc-2 and Bottleneck 07:06.

    The readings behind the reply, as chips

    Ask · every claim cites its sourceStep 2 of 5

    The readings behind the reply, as chips

  3. Step 3: Cost

    The Waste Ledger ranks the finding first at €6,694 a week, inside €7,085 at stake for the Top-5. Each row shows what was measured, the rate and a confidence.

    Top-5 table of the Waste Ledger. Rank 1, CNC cell 2 bottleneck, shows 80,330 s starved, a rate of €420 an hour and €6,694 per week.

    Rank 1: CNC cell 2 bottleneck, €6,694 a week

    Waste Ledger · simulated plantStep 3 of 5

    Rank 1: CNC cell 2 bottleneck, €6,694 a week

  4. Step 4: Fix

    Open a finding and two buttons wait: Start work and Ask why. Below them the alarm list keeps the CNC cell 2 bottleneck, Outfeed conveyor starved 98%, at 07:06.

    Start work and Ask why buttons, and below them the alarm list. The first row reads CNC cell 2 is the bottleneck, Outfeed conveyor starved 98%, 07:06.

    Start work and Ask why

    Finding · actions and alarm listStep 4 of 5

    Start work and Ask why

  5. Step 5: Floor TV

    The same bottleneck shows on the wall. The LINE 1 ANDON screen lists each station's state in words, with a P1 marker on CNC cell 2.

    A wall-mounted screen in a factory hall showing the LINE 1 ANDON board with IDLE and RUN stations and a P1 marker under BOTTLENECK 50% on CNC cell 2.

    The same bottleneck, marked on the wall screen

    Andon · wall screenStep 5 of 5

    The same bottleneck, marked on the wall screen

Live on the floor

The LINE 1 ANDON board is built to be read from across the hall. Every station says RUN or IDLE in words and draws its own shape, a filled square or a hollow one, so colour is never the only signal.

The timers on this board count up every second, as they do on the real screen.

Larkfield Precision · Plant 1 (simulated)Live demo, ticking in your browser

From photos to a ranked list

Six steps take the files you already have to a list you can act on this week.

  1. 01

    Plan

    Upload photos, drawings and manuals. ReduceWaste proposes a monitoring plan and a sensor shopping list, with the reason for each sensor.

    Why this sensor, for CNC cell 1: goal Count cycles, method spindle-load and where to clamp the sensor.
  2. 02

    Instrument

    Fit the sensors, then check each signal as it arrives: data, rate, range and calibration.

    Commissioning list for CNC cell 1. A plausible power-meter signal and a missing vibration signal with a channel picker and a Connect button.
  3. 03

    Ingest

    Every input lands in one namespace: Modbus, OPC UA, MQTT sensor nodes and cameras, sorted by plant, area and line.

    A tree of inputs on the left feeding Plant 1 in the middle, which branches into press-shop and utilities.
  4. 04

    Analyze

    Trends and spectra are read against limits such as the ISO 20816-3 vibration zones.

    A vibration trend climbing from zone A into zone C, with the start of a spectrum and an evidence panel under it.
  5. 05

    Pinpoint

    Each finding sits on the floor plan beside its machine, with a link to its evidence.

    Findings list entry 2: CNC cell 2 is the bottleneck, Outfeed conveyor starved 98%, with an Evidence link.
  6. 06

    Reduce

    OEE by shift sits beside every machine's timeline, so the effect of a fix can be compared from one shift to the next.

    OEE by shift for Shift A, C and B with availability, performance and quality, above the start of the station timelines.

Films

Watch ReduceWaste read a plant, raise an alarm and rank what it costs. Every film has captions.

Built for where people stand

The desk

Engineers

A camera inspection model with an inspection score of 0.973 against a minimum of 0.95, and an Activate button.

Engineers review a camera model's score against its minimum before they activate it.

The line

Operators

Station timelines for the stamping press, two CNC cells and the outfeed conveyor, drawn as dark Run and light Idle bars.

Each station's state over the shift as Run and Idle bars, with its power beside it.

The office

Managers

Site setup, Goals: twelve options including Count cycles, Machine state, Energy use and Cut scrap, each with a tick box.

Managers set the goals the plant should measure first, such as counting cycles or cutting scrap.

It stays in your plant

ReduceWaste runs on hardware inside your plant. The edge reader is the only component that talks to field devices, and it sits in a DMZ-style position relative to the OT network. Modbus write function codes are rejected in code, and OPC UA sessions are opened read-only.

  • Read-only toward machines
  • No cloud subscription
  • Air-gap capable

OT safety and IEC 62443 Air-gapped install

Where ReduceWaste sits in the plant Inside the plant boundary, three machines connect by read-only links to an edge reader in a DMZ, which connects to one on-site server. No cloud sits in the path. INSIDE YOUR PLANT PLANT MACHINES EDGE READER ON-SITE SERVER read-only on your network only part that talks to machines DMZ historian, app and analysis

Measured, not claimed

Eval scores, measured on the bundled sample factories.

Survey recall
0.98
Finding the machines and candidate measurement points a factory actually has, from photos, drawings and documents, across 10 sample factories.
Analyst recall
1.00 false findings
Catching every seeded fault across 24 scenarios on the demo plant, with no findings that aren't real.
Answer grounding
0.9974
Every claim in an answer traces back to a real reading, event or document.
Sensor BOM validity
1.0
Every proposed sensor line is a valid, buildable part of the monitoring plan.
CV anomaly detection
0.99AUROC
Camera-based defect detection on the sample anomaly set.

21 languages

ReduceWaste ships in 21 languages across the app, the documentation and the sensor recipe library, including right-to-left Arabic.

  • English
  • 中文（简体）
  • हिन्दी
  • Español
  • العربية
  • Português (Brasil)
  • Русский
  • 日本語
  • ਪੰਜਾਬੀ
  • Deutsch
  • Français
  • 한국어
  • Türkçe
  • தமிழ்
  • Italiano
  • Polski
  • ಕನ್ನಡ
  • Bahasa Indonesia
  • Nederlands
  • Tiếng Việt
  • ไทย
Site overview in Arabic, mirrored right to left, with the alarm summary and the CNC cells.
Site setup, step 1: a grid of the 21 languages with English selected.

For integrators

Deploy and size sites for clients, from a single-box demo to a multi-line plant split across several boxes by role. The same engineer-facing surface works across every site you administer.

See the integrator page

Bring it to your plant.

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Film