FoundryPulse
Real-time manufacturing performance monitoring
FoundryPulse is a production monitoring platform built for a metal casting facility. It replaces manual data collection with live dashboards that show line status, output rates, and downtime — giving floor managers and leadership a shared, real-time picture of what's happening in the plant.
Challenge
The facility tracked production on paper and spreadsheets. Shift reports were delayed, downtime causes were hard to pinpoint, and management had no real-time view of output. When issues occurred, it took hours to identify the root cause — and even longer to measure the impact.
Solution
We built a React + TypeScript dashboard connected to the production floor via WebSocket. Data flows from machine signals into PostgreSQL, where it’s aggregated into live KPIs: OEE, cycle times, reject rates, and downtime breakdowns. The UI updates in real time and works on both desktop screens in the office and tablets on the floor.
Key Features
Live production dashboard
Floor managers see line status, output counts, and cycle times updating in real time — no manual refresh needed
Downtime tracking & classification
Every stop is logged with a reason code. Weekly reports show exactly where time is lost and which causes repeat
Shift-based reporting
Automatic shift summaries replace handwritten logs — output, rejects, and downtime broken down per shift and per line
Role-based views
Operators see their line. Shift leads see the floor. Management sees plant-wide trends and comparisons