GembaFix™System Overview
Complete data flow from shop floor to executive dashboards
Built for Scale
Modern stack designed for manufacturing environments
Shop Floor
6 TWINEX93 Production Lines
Line 1
Extrusion + Orientation
Line 2
Extrusion + Orientation
Line 3
Extrusion + Orientation
Line 4
Extrusion + Orientation
Line 5
Extrusion + Orientation
Line 6
Extrusion + Orientation
Digital Capture
Mobile/Tablet Entry with Validation
Extrusion Log
35+ fields
Orientation Log
25+ fields
Quality Check
22 checks
Downtime Log
16 codes
Inventory
6 materials
Changeover
15+ fields
Supabase Database
Real-Time PostgreSQL with Row-Level Security
chemfab_production_lines
chemfab_product_specs
chemfab_operators
chemfab_shifts
chemfab_extrusion_logs
chemfab_orientation_logs
chemfab_quality_inspections
chemfab_downtime_events
chemfab_downtime_reasons
chemfab_defect_master
chemfab_alerts
chemfab_bom_materials
chemfab_inventory_consumption
chemfab_changeover_logs
Role-Based Dashboards
Real-time Analytics by Permission Level
Admin
- User & Role Management
- System Settings
- Plant Configuration
- Audit Logs
Plant Head
- Total Production vs Plan
- Line-wise Comparison
- Downtime Pareto
- Yield Trends
Supervisor
- Approval Requests
- Shift Handover Summary
- Escalations
- Operator KPIs
Operator
- Live Line Status
- Enter Shift Readings
- Report Downtime
- Confirm Changeovers
Quality
- Rejection % by Line
- Defect Trends
- Process Alerts
- Rework Analysis
Adding AI on Top of Your Data
The data we're capturing becomes the foundation for powerful AI. Two approaches - one available immediately, one that grows with your data.
LLM-Based Intelligence
Available now with existing data
Available Models (2026)
Closed-Source (API)
Open-Source (Self-hosted)
Natural Language Queries
Ask questions in plain English
"What was Line 3's rejection rate last week?"
"Line 3 had 2.3% rejection last week, up from 1.8% prior. The spike occurred Thursday on Shift 2."
Auto-Generated Reports
Human-readable shift summaries
Generated Summary:
"Shift 1 produced 42 pipes with 97.6% acceptance. One 30-min downtime for material feed. Melt temp stable at 184°C."
Troubleshooting Assistant
Analyze data, suggest causes
"Wall thickness is varying. What should I check?"
"Haul-off speed fluctuated ±0.3 mpm in last 2 hours. Die temp zone 4 is 3°C below target."
Implementation Status
Coverage against the Process Digitization Proposal
Implemented in POC
Needs ChemFab Input
Machine Integration Options
Three paths to evolve from manual entry to automated data capture
Manual Entry
Tablet/phone data entry validates workflows
- Operator enters readings hourly
- Form validation catches errors
- Data flows to dashboard instantly
Hybrid Capture
OCR + selective machine integration
- Scan existing paper forms
- Connect machines with REST/MQTT
- Operators verify auto-populated fields
Full Automation
SCADA/PLC direct integration
- All readings from machines
- Operators handle exceptions only
- Real-time alerts on deviations
Machine Integration Architecture
SCADA/PLC
Modbus, OPC-UA, MQTT
Node-RED Gateway
On-site data transformer
Supabase
REST API ingestion
Dashboard
Real-time visibility
Node-RED runs on a Raspberry Pi or small server at the plant, bridging industrial protocols to cloud