A medium-scale mill running 20–100 t/day across 2–4 machines faces a coordination problem that a single planner cannot solve manually. Deckle Plus connects planning, floor execution, and inventory into one system, giving the planner control and management the visibility they need.
When a mill adds a second machine, the planning problem doesn't just double, it multiplies. Orders must be split across machines by grade, width, and due date. Inventory must be allocated across machines on FIFO basis. Floor execution on two machines must be tracked simultaneously. And management needs to see total production, not just one machine's log. This is where manual planning breaks down, and where a purpose-built system creates its biggest impact.
A paper mill in Ludhiana, Punjab produced Kraft and Duplex board on three machines: a 3600mm primary winder, a 2400mm secondary winder, and a 1800mm rewinder for narrow orders. The mill ran two shifts per day and employed two planners who split machine responsibility informally: one managed the primary winder, the other managed the secondary and rewinder.
The informal split worked until a senior planner resigned. The mill's owner had to step in as a third planner while hiring. During this period, the inventory problem became critical: Kraft liner meant for the primary winder was being consumed by the secondary (which loaded it by mistake), and FIFO tracking broke down entirely. Three weeks of emergency overtime and rework were needed to reconcile the inventory before the next physical count.
After deploying Deckle Plus Suite, all three machines were configured under one account. Orders were entered once and assigned to machines based on grade and width. FIFO inventory allocation was automatic; the system showed exactly which parent reel was loaded on which machine and deducted consumption in the correct sequence. The two remaining planners both worked in the same system, with shift handover notes attached to each open run. The owner stepped back from planning entirely within six weeks.
Result
Inventory reconciliation errors dropped to zero. Planner coordination time reduced by 60%. Management gained real-time waste and production visibility for the first time.
The Suite plan supports unlimited machines under one account. Each machine has its own deckle width, blade count, and waste targets. Production runs are assigned per machine and tracked independently, with consolidated reporting across all machines for management.
Admin, Planner, Operator, and Supervisor roles are configurable per user. Planners create runs and confirm patterns; operators execute on the floor and log waste; supervisors close runs; admins manage machine and user configuration. Each role sees only what they need.
Inventory is managed centrally and allocated to machines on FIFO basis. When a planner assigns a Kraft run to Machine B, the system allocates the oldest available Kraft stock from inventory, regardless of which machine received it at intake.
Open production runs carry notes, pattern status, and waste log through shift handovers automatically. The incoming planner opens the run and sees exactly where the previous shift left off: which patterns are complete, which are in progress, and which waste events were logged.
The analytics screen shows daily production per machine, waste trend by machine and grade, pending order backlog, and inventory stock levels, updated in real time. Management gets the daily summary without waiting for the planner to compile it.
Specific questions about how Deckle Plus handles this use case.
In Deckle Plus, production runs are assigned to a specific machine by the planner. When creating a new run, the planner selects the machine, and only orders compatible with that machine's deckle width (i.e., narrower than the deckle) are available to add. The planner decides which machine handles which orders based on grade and width suitability. This replaces the informal verbal allocation that most multi-machine mills currently use and creates a documented allocation record per run.
Yes. Deckle Plus is a multi-user cloud platform. Two planners can create and manage separate production runs on different machines simultaneously without conflict. Each run is a separate record; there is no shared spreadsheet that two people overwrite. When both planners need to access the same inventory or order queue, the system handles concurrent access correctly, and order assignments are locked when a run is confirmed.
The Deckle Plus analytics screen aggregates production data across all machines. Management sees daily tonnage per machine, waste percentage per machine per shift, pending order backlog by grade and due date, and inventory stock levels, all updated in real time. Weekly trend charts show whether waste is improving or worsening per machine. This replaces the daily summary the planner currently compiles manually, and it is available 24/7 without requiring a report request.
The Suite plan supports unlimited machine lines; adding a third machine in 6 months requires only a 10-minute configuration in the machine setup screen. No plan change or additional per-machine fee is required. The new machine appears in the dashboard, optimization, and inventory allocation immediately after configuration. This is one of the key reasons growing mills choose Suite over Basic from the outset.
A 3-machine mill typically completes onboarding in 3–4 days. Day 1: machine configuration, paper type setup, and first order entry with our onboarding team. Day 2–3: first production runs on each machine, operator training on floor execution, and inventory intake logging. Day 4: management dashboard review and analytics walkthrough. From week 2 onward, the team runs independently with support available via email and WhatsApp.
Book a 20-minute call. We'll confirm Deckle Plus fits your specific workflow and show you a live optimization on your order data before you invest any further time.