Simplify your manufacturing operations

Good information is critical to running manufacturing operations efficiently. If you are still relying on hand-written data, complex spreadsheets and whiteboards, then discover how KT-Pulse can connect your team with more accurate insights in real-time, so that you can focus on managing an efficient operation.

Simplify your manufacturing operations

Good information is critical to running manufacturing operations efficiently. If you are still relying on hand-written data, complex spreadsheets and whiteboards, then discover how KT-Pulse can connect your team with more accurate insights in real-time, so that you can focus on managing an efficient operation.

New insights with

Sometimes you just want to see if production is on track

Other times you want to plan what builds to prioritise

You might need to know what issue you need to focus on right now

Or to understand why targets are missed

For others, it’s about knowing where to focus improvement activity

But regardless of what you need to know

KT-Pulse provides you with the answers at a glance

Digitise your manufacturing performance data

We know how frustrating and time-consuming it can be to get an accurate picture of how your assembly lines, inspection cells and packaging areas are performing. Tally counters, checksheets, spreadsheets and whiteboards are the standard tools for piecing your story together.

KT-Pulse replaces these tools with an easy-to-use platform, giving you more accurate insights, in real-time on easy-to-read dashboards. Eliminate the time spent creating reports and focus on running an efficient manufacturing floor with KT-Pulse.

Discover your true manufacturing potential

There are many things that contribute to lost productivity, poor quality, missed shipments and excessive overtime. But it can be difficult to get an accurate measure of each, and even more difficult to get the information in real time, leading to unnecessary delays and cost overruns. Discover new insights and opportunities to increase productivity and efficiency with KT-Pulse.

Changeovers

It can be difficult to measure how long changeovers really take. This is even more complex when unplanned issues arise during changeovers. KT-Pulse is helping to accurately quantify the impact of wait time on changeovers. Waiting for raw materials, paperwork and technical support are doubling and trebling changeover times. This is triggering projects to overhaul changeover processes and significantly increase uptime.
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Defects

The cost of defects can have a significant effect on the bottom line. Tracking defects in real time is helping our customersto discover trends that are difficult to see, such as ‘time of day’ effects. This is not always obvious when batches are produced over multiple shifts. Trending helps to discover subtle differences in techniques across shifts, which is driving breakthrough levels of quality.
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Flexing

Some manufacturers have a team of production operators who flex between multiple production lines. This helps to cater for fluctuations in demand, but is it efficient? KT-Pulse helps customers to identify significant differences in performance depending on the number of operators on the line at any one time, and more operators does not always lead to more output (too many cooks syndrome). KT-Pulse helps identify which combinations of operators work best and which ones to avoid.
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Startupitis

Startupitis describes anything that stops a production line from getting into a rhythm at the start of a shift. It affects any line that doesn’t have a clear start-up process. Waiting for instructions on what to do, unpacking materials, equipment setup and counting are just some of the causes. KT-Pulse helps to measure the impact of Startupitis and points to where improvements can be made. This is helping customers to transform their start-up process and increase productivity.
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The small stuff

The big issues are usually easy to spot. However, the smaller and recurring issues can quickly add up to a lot of lost time too. In one case, KT-Pulse was used to log 125 downtime events over 2 weeks, with an average of 3 minutes per event (that’s 6 hours downtime for 10 operators!). In this case a machine kept breaking down, causing short disruptions to momentum on a regular basis. The machine was overhauled and the team’s productivity significantly increased as a result.
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Connect your whole team

Hidden beneath the surface of any production line are the real challenges that impact productivity every day. KT-Pulse presents manufacturing data on easy-to-read dashboards that enables your team at all levels of the organisation to work together and to drive sustainable improvement.

Connect your whole team

Hidden beneath the surface of any production line are the real challenges that impact productivity every day. KT-Pulse presents manufacturing data on easy-to-read dashboards that enables your team at all levels of the organisation to work together and to drive sustainable improvement.

Give your operators a voice

Frontline operators are the most critical asset in any manufacturing business. They generally have a very good understanding of the problems, but struggle to quantify them accurately. Through our simple touchscreen interface, operators capture good units, rejects, downtime and changeovers in real time, giving them a new way of characterising the challenges. Our tablet is located right where the operators work, so there’s no retrospective data entry and no guesswork. Every event is logged in real time with accuracy. Just seconds of their time every hour.

Bring clarity and focus to your team meetings

Whether it’s a daily production meeting that focuses on the current status of manufacturing or a continuous improvement meeting where historical trends are more relevant, our suite of dashboards can give you the insights you need – one consistent, accurate and real-time version of the truth, right across the organisation.

Focus on the biggest problems

Lots of issues arise on the manufacturing floor every day. Our live dashboards allow you to view all production areas at a glance, so you can target your resources to the areas of greatest need first. Rapidly respond to all critical issues with our real-time dashboards.

Increase the effectiveness of your frontline managers

By combining the insights from the KT-Pulse dashboards with our online training, frontline managers are learning to manage their manufacturing environments more effectively. For the less experienced team leads and supervisors, our focused workshops provide an additional level of coaching to help build the leaders of the future.

Empower your team to succeed

All of our dashboards are accessible through a web browser on one easy-to-use platform. So whether it’s a team meeting at a large touch screen monitor, or an individual accessing the analytics remotely on their laptop, KT-Pulse enables your organisation to stay connected and work towards a common set of goals. By encouraging your teams to uncover all the problems and by giving them the means to bring forward ideas and solutions, your teams are inspired to make lasting improvements together.

Save time and money

Eliminating time-consuming paper-based reporting, responding to issues more quickly and better team collaboration are just some of the ways that KT-Pulse can help you to run your manufacturing operations more efficiently. By giving time back to your support teams and guidance on where to target their energy, your organisation will save money in many ways. Here are some KT-Pulse customer examples …

%

DOWNTIME REDUCTION

Downtime issues were taking too long to resolve. KT-Pulse helped to prioritise where to focus and the impact of line stoppages were reduced by 50%. This enabled the customer to consistently achieve the weekly build plan within a standard working week.

%

PRODUCTIVITY INCREASE

Startupitis was prevalent within a customer site and the first hour’s output was consistently below plan. The startup issues were quantified and new work practices were introduced, eliminating 90% of the issues. Output increased and one operator was freed up for a new project.

%

INDIRECT LABOUR REDUCTION

Line leads were spending 2 hours per shift creating output and downtime reports. This kept them away from the front line for large periods of time, and overtime was needed to finish reports. KT-Pulse automated the reports, helping the leads to run a more effective shop floor within a standard working week.

EPC

“EPC are using KT-Pulse in several ways including manufacturing performance tracking and the measurement of improvements during kaizen events. The benefits include rapid identification and response to real-time production issues and accurate capture of production data.”

– PJ Merrigan, Senior Project Manager, EuroPharma Concepts

The power of KT-Pulse

Tell us about yourself and see how KT-Pulse can make managing your production floor easier

Whether it’s giving time back to your support team, reducing the impact of downtime

or increasing your productivity

ROI Calculator

Tell us where you are today

How many critical assembly, inspection and packaging processes do you need to monitor?

How much time per week does your team spend creating production reports (e.g. 8 people x 2 hours = 16 hours)?

How much downtime per week do you experience across the producton floor (e.g. 30 people x 4 hours = 120 hours)?

How much overtime do you need to run per week (e.g. 8 people x 6 hours = 48 hours)?

This is what you could have tomorrow

Based on feedback on how customers are benefiting from KT-Pulse, this is what we project for you and your team

Projected Benefits

90%

less time creating reports

30%

reduction in downtime

60%

reduction in overtime


Projected Savings per week

0hrs

less time creating reports

0hrs

reduction in downtime

0hrs

reduction in overtime


0

Annual Savings

0 months

Return on Investment

Bringing the operations team together

KT-Pulse is designed for the whole manufacturing team, not just experts. Our 4-step process quickly delivers new insights, resulting in clear improvements to your business.

SETUP

Configure any assembly process

Customise a range of parameters to suit your unique production environment and adjust them whenever you want

 

  • Give your production lines and teams their proper names
  • Add part and batch numbers to track on-time delivery
  • Set shift start, finish and break times to match your schedule
  • Auto adjust hourly targets for breaks and part number changes
  • Set scrap and downtime reasons that make sense to you
  • And many more parameters for your unique environment

COLLECT

Measure at source

Log production data quickly and easily in real time, right where the production operator is working. Capture all events precisely, through the expert eyes of the frontline workers…  

 

  • Accurately quantify good units produced in real time
  • Capture defects to detect changes in quality
  • Quantify the impact of rework at critical processes
  • Log downtime precisely, regardless of how big or small
  • Measure batch changeovers precisely
  • Discover the true lead time of your processes

IMPROVE

Base decisions on good data

Navigate between real-time insights for better daily management and longer term trends for deeper understanding of improvement opportunities

 

  • Check if production output is on track at any time of the day
  • Spot the areas with the greatest need of support
  • Monitor key performance indicators over time
  • Discover problems that you never knew existed    
  • Identify improvement projects with the greatest impact
  • Keep up-to-date on the go, when you’re not on the shop floor

STANDARDISE

One team, one approach

Create a standardised approach to how you manage operations at all levels of the organisation  

 

  • Rapidly respond to the biggest issues first
  • Measure all manufacturing areas the same way
  • Get everybody aligned with more productive daily meetings
  • Create a culture of openness in discussing the real issues
  • Coach and support your teams to deliver lasting changes
  • One version of the truth for the whole team
Aerogen

“With KT-Pulse, we can carry out analysis that wasn't possible before, certainly not to the required level of detail and confidence. Specifically, we can now determine the optimum resource level for each product code.”

– Robert O’Connor, Manufacturing Engineer, Aerogen