Skip to content
woodfrog
Industries · FMCG

More cases per shift. Less giveaway.

For food, beverage and personal care plants. We connect packing lines, checkweighers and SAP so every SKU runs faster and leaner.

Contact usAt least 3× return within 12 months.

Where a typical packing line loses its time

Illustrative
Planned timeChangeoversSmall stopsSlow speedRejectsOEE

More SKUs mean more changeovers. Small stops never reach the report. We show each loss by line, SKU and shift.

The numbers we move
  • OEEOn every packing line
  • ChangeoverMinutes from last good to first good
  • GiveawayProduct given away above declared weight
  • Scrap %Material and packaging lost
  • Forecast accuracyPlan against actual demand
  • Fill rateOrders shipped in full
  • OTIFOn time, in full
  • Cost per caseAll in, per SKU
Problems we fix

Five problems every FMCG plant head knows.

Cost figures are illustrative, not woodfrog results, unless linked to a case.

A beverage bottling hall with conveyors carrying green bottles and stainless steel control cabinets
What it costs
Minutesper changeover, many times a day
SKUskeep growing, lines do not
01Changeover

Changeovers eat the shift

Changeover time is written on a sheet, if at all. Nobody sees which SKU sequence costs the most.

What we do
DATAChangeover start and end from the line PLC
ANALYTICSChangeover time by SKU pair and crew
AISuggested SKU sequence that saves the most time
DATAPLC · MES
Empty glass bottles lined up on a filling machine with a hand wheel
What it costs
Gramsper pack add up to tonnes a year
Rejectswhen fillers run too close
02Giveaway

Giveaway above declared weight

Fillers are set high to stay safe. Checkweigher data is seen but not used to tune the line.

What we do
DATAEvery checkweigher reading kept
ANALYTICSGiveaway by line, SKU and filler head
AIAlert when a filler drifts high or low
DATACheckweighers · Fillers · PLC
Aluminium cans passing a labelling machine on a packing line
What it costs
Secondsof stops, hundreds of times a shift
Caseslost that never show in the report
03OEE

Small stops nobody records

Operators restart the machine and move on. The shift report says the line ran.

What we do
DATAEvery stop captured from the PLC
ANALYTICSOEE and stop Pareto by line and shift
ANALYTICSSpeed loss against rated speed
DATAPLC · SCADA
Tall warehouse racking with wrapped pallets of cardboard cartons
What it costs
Stockof slow SKUs piling up
Stockoutson the fast ones
04Forecast · Plan

Production plan out of step with demand

Sales forecast, production plan and distributor stock sit in different places. The plant learns of a change last.

What we do
ANALYTICSForecast accuracy by SKU and region
DATADistributor stock and orders in one view
AIPlan changes flagged before they hit the line
A sealing machine closing a foil pouch on a green conveyor belt
What it costs
$240ka year caught in one woodfrog case
Weeksbefore the leak shows in the P&L
05Cost per case

Material and freight cost leaks

Agreed prices and actual invoices drift apart across many suppliers. Nobody checks every line.

What we do
AIAgreed price against invoice, every line
ANALYTICSLanded cost per case, by SKU
ANALYTICSSupplier scorecards on price and delivery
DATASAP · Tally · InvoicesCase: Margin leaks caught before close →
Done before

Already paying back in consumer goods.

All case studies →
Systems we connect

From the filler to the distributor.

Lines
Fillers, checkweighers, cartoners, PLCs
Shop floor
MES, SCADA, OPC UA gateways
Supply
DMS, distributor stock, demand forecasts
Business
SAP, Tally, Excel

Read only to start. Nothing writes back to the line until you approve it.

PLC · CheckweigherYour plant
Antvia DataOne governed store
OEE · Giveaway · OTIFLive views
A stainless steel can filling machine with aluminium cans on a conveyor
Who you work with

Engineers who have stood by the packing line.

Ananta PatilSamruddhi MoreMandar JoshiParth ManhasPranjul KalsiNarendra P

A small team from Pune, India. The people who walk your site are the people who build it.

Meet the team →
Where we have built
Grocery retailSupplier cost leaks caught two weeks before close.
Process plantBatches, stock and GST paperwork in one record set.
Data foundationsOne owned definition per measure, with full lineage.
Our promise

At least 3x return, within 12 months of delivery.

Measured on your own numbers: cases per shift, giveaway, scrap and cost per case.

How we measure it →

Questions FMCG plant heads ask.

Do you need new sensors?

Usually not. Most of what we need is already in your PLCs, fillers and checkweighers. Where a signal is missing, we say so in the first audit and suggest the cheapest way to capture it.

Will this disturb production?

No. We start read only, connecting to the data your lines already produce. Nothing writes back to the line until you approve it, and we plan any site work around your shifts.

Can you handle hundreds of SKUs?

Yes. Every measure is built per SKU, so changeovers, giveaway and cost per case can be read by SKU, SKU pair, line or shift. A long SKU list is the reason the numbers get hard to see by hand.

Can data stay inside the plant?

Yes. The data store can run on your own servers or in your own cloud account, on open formats, so you are never locked in. We work inside your IT and security rules.

How soon do we see results?

The first live view, for the line we start with, typically comes within the first weeks of the build, once the signals are connected. The audit sets the exact plan for your plant.

Rows of dark glass bottles moving along a bottling line
Tell us your changeover time.We will show you how to win it back.

Talk to us about your lines

Or record your message instead
A person replies within one business day.WhatsApp us