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AI agent for packaging engineers

Pilot to Plant Costing Agent

A cost per unit at plant scale with every assumption checked against plant data.

Budgets and moneyScience and researchProduct development
See how it worksGet access
Pilot to Plant Costing Agent: what goes in, what the agent does and what you get

What it does

A pilot batch looks cheap, then the plant quote is 30 percent higher because yields, labor and changeovers behave differently at scale. This agent takes pilot yields and labor times and scales them using plant data, such as line speed, scrap rates, labor crews and changeover times. It computes a cost per unit and checks each assumption against plant records of similar products. When an assumption does not match history, it updates it and reruns. It shows the cost build with the weakest assumptions highlighted. You approve the costing. Edge case: pilot yield from a batch that included rework is adjusted before it is used.

How it works

Follow the arrows from top to bottom. The orange dashed arrow is the loop: when a check fails, the agent goes back and tries again.

Start and resultWhat it doesA check on its own workWaits for your OKGoes back and retries
Yes, continueYes, continueApprovedNoNo 1 STARTS WHEN Pilot run complete 2 USES A TOOL Read pilot yields, labor times and the recipe 3 DOES Adjust pilot figures for rework or test effects 4 USES A TOOL Load plant data for line speed, scrap, crew size andchangeovers 5 DOES Scale yield, labor and changeover to the plant 6 DOES Compute cost per unit: ingredients, labor,packaging, overhead 7 CHECKS THE RESULT Is each assumption inside the plant's historicalrange for similar products? If not: replace it with the historical value andrecompute. Back to step 4. 8 DOES Run a sensitivity on yield, line speed and price 9 CHECKS THE RESULT Is the cost per unit under the target price aftersensitivity? If not: list the levers that close the gap, such asyield or pack size. Back to step 6. 10 YOU APPROVE Developer approves the costing 11 RESULT Cost build and assumptions list
Read the steps as a list
  1. Pilot run complete
  2. Read pilot yields, labor times and the recipe
  3. Adjust pilot figures for rework or test effects
  4. Load plant data for line speed, scrap, crew size and changeovers
  5. Scale yield, labor and changeover to the plant
  6. Compute cost per unit: ingredients, labor, packaging, overhead
  7. Is each assumption inside the plant's historical range for similar products?If not: replace it with the historical value and recompute. Back to step 4.
  8. Run a sensitivity on yield, line speed and price
  9. Is the cost per unit under the target price after sensitivity?If not: list the levers that close the gap, such as yield or pack size. Back to step 6.
  10. Developer approves the costingThe agent waits here for your OK.
  11. Cost build and assumptions list

How it decides

It scales pilot figures by plant factors and replaces any assumption outside the plant's historical range with the historical value.

  • Pilot yield higher than any plant yield for similar products: use the plant range
  • Changeover time missing: use the average for the line
  • Cost over target by under 5 percent: list levers
  • Overhead rate unknown: ask finance and show the cost without it

Make it yours

Every agent is a starting point. You choose these settings for your own situation.

  • Plant lines to use
  • Historical data window
  • Target cost
  • Overhead rates
  • Sensitivity ranges

What keeps you in control

It always asks you first

  • The final costing

Hard limits

  • Never quote a price to customers
  • Never use an unsourced assumption without labeling it

It stops when

  • Done: costing approved
  • Stop: plant data unavailable

Set it up

We guide you through the set-up, step by step

Members get the full set-up guide for this agent. No technical skills needed: you copy, paste and upload.

10 minto set it up in your AI
5 AIsChatGPT, Claude, Copilot, Gemini, Grok
  • One set of instructions to paste into your AI, with the clicks for ChatGPT, Claude, Microsoft 365 Copilot, Gemini and Grok
  • The agent then walks you through connecting your own data, one source at a time
  • A downloadable copy with the flow chart, the rules and the full guide
Get access to this agent

An example run

What happensA pilot for a granola bar reported 94 percent yield and 6 labor hours per 1,000 kg. The plant's similar products ran at 89 to 92 percent yield, so the check failed. The agent used 90 percent and added a changeover of 45 minutes. Cost per unit rose from 0.31 to 0.36 against a 0.34 target. It showed larger pack size and 92 percent yield as levers. The developer approved the costing.

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