HIDDEN LEAK #04 · PRODUCTION
Every Roll of Wasted Paper Is Profit Walking Out the Back Door. Sometimes Literally.
4 of 24 leaks diagnosed
Untrackedwastage above planned norms
Most owners have never measured this on their own floor. needs real data
⚠️The Problem
Wastage is estimated at quotation as a flat percentage, but actual wastage (makeready, quality rejects, scrap handling) is never measured against that estimate, and scrap disposal is loosely controlled.
💥The Impact
- Real wastage silently erodes margin the P&L can't explain
- Scrap with resale value goes untracked, sometimes leaving the gate unrecorded
- No data exists to negotiate better makeready practice or hold crews accountable
🔍Root Cause
Wastage is just a guessed percentage in the costing sheet, nobody measures the real number on the floor.
🔧The Fix
Track wastage as a real number, not a guess, record it the moment it happens.
✅The Solution
- Job-wise wastage capture at every production stage
- Scrap and dead-stock register with disposal tracking
- Actual vs. planned wastage variance reports by machine and operator
ManualProcess today
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Calculate My Number ↓See what this leak is costing you
People on payroll60
Per employee₹25,000
% of team time12%
Illustrative annual impact ₹21.6 L A directional estimate from your inputs, not a guarantee. Your real number comes from a 30-Day Automation Assessment.
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