When major gains in productivity were needed to improve profitability, lack of KPI visibility meant work-teams had no immediate idea of how their day-to-day performance was going compared to their own benchmarks, or against other teams. Also, reliance on human reports about which heavy-machinery settings were being used by work-teams allowed an entrenched frontline culture to prevail in compromising equipment safety.
As part of an organisation-wide BI solution developed by Pulse Analytics, more than 300 sensors were installed on each key piece of heavy machinery operated by teams on the frontline. Data from machine sensors was integrated with data from other sources including the organisation’s ERP system. Analysis of the integrated data is displayed on easy-to-read BI dashboards showing actionable KPIs on performance, productivity, profitability, and more in virtual real-time.
Pulse Analytics revolutionised the ability of management to achieve improved profitability through fully-informed decision-making, as would be expected. It was at the frontline, however, where more surprising gains and improvements were made through the responses and interactions of teams and individuals with BI dashboard information including team-productivity KPIs and machine performance data. Live BI dashboards are displayed on TV-screens in the ‘muster room’ where work-teams gather before and after shifts. With teams easily able to compare their performance statistics with each other, the spirit of competition between teams is driving ever-increasing gains in frontline productivity and efficiency, translating into increased profitability for the organisation from the ground-up. The safety of equipment operation is also greatly improved now that everyone at all levels can see when machines are running on recommended settings.