For factories running 20–50 machines

Your factory tells you.
You stop going to find out.

A sensor on every machine, a real cost on every unit, and the few things that need a decision brought to you. Your day goes to growing the business instead of finding out what happened in it.

Book a demo See how it works

A small box on the outside of the machine. A plug point and a WiFi signal. Nothing opened, nothing drilled, nothing rewired. That is the whole installation.

Stopped · 14 min
MACHINE 04
$184
margin not made while it stands
Shed A · today sample
18,642 m
woven across nine machines
True cost$6.71 / m
Profit today$3,052
Jarvis — MACHINE 04 has been down fourteen minutes. Belt slip, same as Tuesday. Shall I raise it with maintenance?
Stopped · 14 min
MACHINE 04
$184
margin not made while it stands
Shed A · today sample
18,642 m
True cost$6.71 / m
Profit today$3,052
Jarvis — MACHINE 04 has been down fourteen minutes. Belt slip, same as Tuesday. Shall I raise it with maintenance?
Production machines · continuous-run · packaging · rope & twine · wire & cable · extrusion · moulding · CNC · foundry · knitting
metreskgparts bagstonnes
— the short version

What actually changes.

Not how it works. What your week looks like once it is running.

Film in production

90 seconds·sound optional
Try this tomorrow

How many calls did you make today just to find out what happened?

“Is machine 4 running?” “How much did the night shift make?” “Did the material arrive?”

Count them tomorrow. Blitz makes every one of those calls unnecessary.

How it works

Three things happen, and then the floor starts talking.

Nothing on the floor changes. No operator learns a new routine. The machines keep doing exactly what they did yesterday — only now they say so.

01

Clip the sensor on.

A small non-invasive sensor goes onto the machine you already own. No rewiring, no PLC, no hole drilled in anything. It reads the machine's own movement.

02

It counts, and it prices.

Every metre, kilo or part is stored the moment it is made — never guessed at the end of a shift. Then material, power, labour and machine hours are put against it.

03

It tells you.

You stop going to look. Jarvis pushes what needs you — a machine down, stock short, money overdue, an order slipping — and answers anything you ask, by text or voice.

What it measures

Six things your floor cannot tell you today.

All six run off the same measured record — what the machine actually did, and the paperwork that actually arrived. Nothing here is typed in at the end of a shift.

Live machine output

What every machine has made, this minute. Counted at the machine, stored the moment it happens.

Downtime, priced

Every stop, how long it lasted and what it cost you in margin — not in vague "lost hours".

True cost & profit per unit

Dollars per metre, per kilo, per part — material, power, labour and machine hours, per product and per customer.

Energy per unit

kWh and dollars per unit — not per bill, at the end of the month, for the whole plant at once.

Material in, by photograph

Photograph the supplier's bill at the gate. Blitz reads it, a person approves it, and clean entries reach accounts and the same stock pool production draws from.

Jarvis, on top of all of it

Ask it what machine 12 did last night, or what you are still owed. Same question box, by text or voice. It answers from the measured record — and tells you what needs you before you think to ask.

True cost

The number no spreadsheet on your desk actually knows.

Not an average across the plant. This metre, on this machine, for this customer — with the power it drew and the hours it held the machine.

Most systems spread the factory's overhead over the metres you made. On our own floor that made one machine's output look like $0.06 a metre when it was really $0.26 — the machine that ran slow and long was carrying the same share as the one that ran fast. Blitz splits overhead by the machine time a product actually used.

And it never adds 12,400 metres to 3,200 pieces. Two different things are two numbers. If an input is missing — a thread nobody has priced, a machine nobody has metered — Blitz names it instead of guessing at it, so the number you quote from is one you can stand behind.

An ERP can show you cost per unit too. It shows you what somebody typed. Blitz shows you what the machine did.

PART No. 25 A · MACHINE 04 sample data
$6.71true cost per metre
Material — raw material$4.0260%
Power$0.8813%
Labour$1.1117%
Machine hours$0.7010%
Sold at $9.20 / m · 41,280 m this month +$1,02,787

What changes the morning you can see it

You re-quote the customer who has been quietly unprofitable for two years. You move a product off the machine that eats power and onto the one that does not. You stop taking the order that looked big and made nothing.

None of that is a new idea. It is simply not possible while the cost per metre is a guess made at the end of the month, from a sheet somebody filled in at the end of a shift.

See it on your own numbers
Jarvis

And then you can simply ask.

Jarvis sits on top of everything Blitz has measured. It raises what needs you without being asked, and answers in the language you would use with your own manager.

Pushed to you · 09:14

MACHINE 04 stopped fourteen minutes ago. That is about $184 of margin not made, and it is the third stop this week — all on the same belt.

What did shed A make yesterday?
18,642 m across nine machines. MACHINE 07 did the most at 2,410 m; MACHINE 04 the least at 980 m — it was down two hours forty.
Is anything I make actually losing money?
One. PP tape 12 mm on LINE 2. You sell it at $7.40 a metre and it costs $7.82 to make there — nearly all of the difference is power. The same tape on TAPE LINE 1 costs $7.05. Shall I show you the two side by side?
How much PP granule is left?
11.4 tonnes. At this month's run rate that is about nine days. The last intake was read off a gate bill on Tuesday — 4,250 kg, approved by Sunil.

Sample conversation, with sample figures. Jarvis answers from your factory's own measured record — sensor-counted production and the paperwork that actually arrived — not from numbers somebody typed.

The difference, in a day

One ordinary Tuesday.

Not what the software does. What the day does.

Today
Six months in
07:40
Walking the shed at 07:40 to see which machines are turning; machine 04 has stopped and nobody knows since when.You walk the shed to see which machines are turning.
Phone alert from 06:14: machine 04 stopped, belt, third time this week, and its job has already moved to machine 07.You knew at 06:14 — Machine 04, belt, the third time this week. The job it was holding is already running on another machine.
08:15
An open paper shift register with handwritten figures, two of them crossed out and overwritten.You read last night's register and chase the crossed-out figures.
A screen showing last night's shift already counted and costed, by machine, next to a cup of tea still steaming.There is nothing to read. Last night is counted and costed — you open the shift and see what it made, by product and by machine, before your tea goes cold.
11:00
A phone call from a customer asking for a price on something never made before, answered with "I will call you back".A customer asks your price for something you have never made. You say you will call back.
Still on the call: a quote built from the closest item already made, this week's material rates, margin on top, and the machines to book, and the customer says yes.You quote him on the call — off the closest thing you have made, at this week's material rates, your margin on top, and the machines you would book to reach his monthly quantity. He says yes while he is still on the phone.
14:00
A supplier bill sitting in a tray at the gate on Tuesday; accounts will not see it until Friday.A bill arrives at the gate. Accounts see it on Friday.
The bill is photographed at the gate and the same numbers go to stock and to accounts on the same day.It is photographed at the gate. Stock and accounts get the same numbers the same day — and that rate is in today's costs, not next week's.
16:30
Stacks of material with no idea whether it will last the month, and a pile of extra bags ordered just to be safe.Is there enough material for the month? You order extra to be safe.
A chart of material running down at the real rate of use, with an alert sent nine days ahead so only what the month needs is bought.You were told nine days ago, at the rate you are actually consuming — so you buy what the month needs, and the cash stays in the business instead of tied up in material you did not need yet.
20:00
At home at eight in the evening, still not knowing whether the day made money.At home, still not knowing whether today made money.
At home in the evening with the phone showing what the day made, and which products and customers made it.You know what today made, and which products and which customers made it. The only thing left is deciding what to run more of tomorrow.

By eight that evening the right-hand column has handed you an order won on the phone, a machine put back to work the same morning, a month's material bought to what you actually use, and the day's profit in front of you. The day stops being one you manage and becomes one you can grow the business in.

Same factory. Same nine machines. Nothing in the right-hand column was asked for.

And then what

The work you never had time to go and get.

Price the job you have never made.

A customer rings and asks for something you have never run. Today you quote from feel, or you pass. Blitz finds the closest thing you have made, takes what that actually cost, prices his recipe at this week's material rates, adds your margin — and tells you which machines you would have to book to make his monthly quantity, cheapest way and fastest way, with the shortfall named if you cannot reach his number.

If nothing you have made is close enough to borrow from, it says so instead of guessing.

And find the customer in the first place.

Blitz finds firms that buy what you make, leaves out the ones you already deal with, writes the first email in your own words, sends it, and keeps a note of who you wrote to and when — so twenty enquiries do not become twenty evenings.

The same search works the other way, for a cheaper supplier.

Why it pays

Measured floors behave differently.

Independent research on this class of system — machine monitoring plus costing — reports the following. These are not our results; they are the range the studies found.

30–50%
less downtime
10–30%
higher throughput
~20%
lower inventory cost

Sources: McKinsey (2022); Aberdeen. Ranges are for the category of system, not a measured outcome at any particular factory. Blitz is built and run in a working factory of our own, not in a lab.

Come and see your own floor lit up.

We set it up — sensors, hosting, all of it. Start with one shed, and see your own machines reporting for themselves, in your own units, in your own currency.

Book a demo See what it measures