The Hidden Cost of Paper-Based Checks: Scrap, Rework, and Lost Profit
Published on: May 07, 2025
Every Shift Should Start With a Process Check — and Paper Just Doesn’t Cut It
From baking donuts to assembling tractors and even launching satellites — every production line shares one universal truth: If the process isn’t right, the product won’t be either.Before a shift starts, operators must ensure everything is within spec. This vital ritual — known by many names — is the first line of defense against non-conforming material and costly scrap.But here’s the problem: in this age of digitalization, too many companies still rely on paper.
What’s the Difference Between First Piece Check, Setup Checklist, and Incoming Inspection
These terms often get mixed up, but while they all share a common goal, they each serves a distinct purpose: catch issues early before they snowball.
1. Setup Checklist: Confirms machines, tools, and parameters are ready to begin production.
2. First Piece Check: Verifies the first unit made meets specifications before running the rest.
3. Incoming Inspection: Ensures raw materials meet quality standards before entering production.
Paper-Based Controls Are Failing Operators
Through our work with numerous manufacturers and food processors, we’ve learned that most still run these critical processes on static paper forms, which introduce big risks:
· No interaction — paper can’t guide or correct the operator.
· False compliance — it’s easy to pencil-whip a check when everything “seems fine.”
· Fatigue and habit — after three daily checks, attention drops.
· Zero visibility — supervisors can’t act in time if they don’t know what’s wrong. “By the time we see the paper, the scrap’s already happened.” – Plant Manager, Tier 1 Automotive Supplier
Digital Workflows with Andonix and AndiX: The New Standard
At Andonix, we believe anyone can perform extraordinary work — especially when guided by smart technology. That’s why our Smart Work Station, powered by our AI copilot AndiX, is built to replace paper and elevate performance.
Here’s how:
- Visual, step-by-step workflows with pictures and videos.
- Digital First Piece and Setup Checklists with real-time validation.
- Smart scheduling that ensures checks are done when needed — not forgotten.
- Anomaly detection and instant alerts to supervisors.
- Photo-verification: Capture gauges, instruments, and evidence — just like a photo-enforced traffic light.
- AI learning: AndiX doesn’t just check — it learns, predicts, and improves future process compliance
Real Value for Real Customers
“We reduced scrap by over $75,000 in just 6 months — and improved training time for new hires by 40%.” — Operations Director, Industrial Components Manufacturer
With Andonix, our customers have seen measurable gains:
· Thousands in scrap savings
· Improved compliance with traceable digital records
· Faster onboarding and built-in tribal knowledge
· Machine connectivity for real-time, autonomous First Piece validations
· Proactive process control, not just reactive correction
Step into the AI Era of Manufacturing
It’s time to move beyond paper, time to empower every operator with tools that ensure quality from the first part to the last — without relying on memory or habit.
Cesar Hernandez is the Director of Customer Success at Andonix. A manufacturing expert, Cesar’s experience includes roles as a Plant Manager, Business Unit Director, and Director of Digitalization. He specializes in helping clients resolve production, quality and compliance issues through digital workflows, IOT and AI via Andonix.