Scrap you paid to make
A batch drifts early and keeps running. The material, the machine hours and the operator time are all spent before inspection catches it.
Retrofit control layer for production machines
Your machine already knows the part is going bad. It just can't act on it.
Reflexivus reads the process while the job runs, recognises the drift that comes before a defect, and adjusts the machine while the part can still be saved. It goes onto equipment you already own.
Sensor pack plus an edge box. Your controller stays where it is.
- Drift caught
- before limit
- Response
- in-process
- Parts scrapped
- 0
Retrofit, not replacement
Edge, runs on the floor
Logged, every correction traceable
The loop
Four things, over and over, for the length of the job.
Most connected machines are open loop. They collect the data, put it on a dashboard, and wait for somebody to notice. Reflexivus closes it.
Sense
Read the process, not the summary
A sensor pack picks up the signals that move before a defect appears: vibration, temperature, sound, spindle load, position.
Infer
Learn the drift signature
Models trained on this machine's own runs separate ordinary variation from the pattern that shows up ahead of one particular failure mode. Different machines drift differently, and a model tuned on somebody else's line will not catch yours.
Correct
Adjust inside your limits
The layer writes a bounded correction back to the controller. You set the bounds.
Log
Leave the evidence
Detections and corrections are both recorded against the job, so quality has something to show an auditor and engineering has something to tune with.
What it catches
The bill arrives after the run is already over.
Rework nobody counts
Parts that pass but need a second operation. The job still ships, so the cost lands in labour instead of the scrap number and never makes it into the review.
Downtime nobody scheduled
Wear signals that were sitting in the data hours earlier, read only once the machine has stopped.
What you measure
We measure the line before we touch it.
A pilot starts by recording how your line runs today. Those numbers get agreed up front, and they are the same ones we report against at the end.
- First-pass yield
- Parts through inspection with no rework, by job and by machine.
- Scrap rate and scrap cost
- Parts lost, plus the material and machine hours those parts consumed on the way to being lost.
- Unplanned downtime
- Stoppage minutes, and how many were preceded by a signal already in the data.
- Cost per good part
- The number finance actually reads.
Fit
Whether your line is worth piloting.
Good fit
- Repeat jobs on the same machines, with recurring defect modes you can name
- Equipment that is instrumented already, or can take a sensor pack and a controller interface
- Somebody in the building owns the scrap number and is measured on it
- One machine and one part family free for a defined pilot window
Not yet
- Defects are one-offs traced to a supplier or a single operator
- The controller is closed and no third-party interface is permitted
- You need a certified turnkey system now rather than a pilot
Start here
Book a line assessment.
Tell us the machine and the loss you keep paying for. You get back what the layer would watch, what it would correct, and whether your line is a fit for an early pilot.
Reflexivus
hello@reflexivus.com
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