Unlocking production potential: how TecnoIndustries leveraged Pulsar to boost efficiency

The Challenge

After expanding in specialized niches, TecnoIndustries decided to enter new markets with its construction products. To do this, they needed to optimize operations and improve pricing margins.

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TecnoIndustries faced the challenge of identifying where to start with their new improvement project. They needed to achieve better control of its operations, given its complex production processes: raw material mining, high fixed costs, and a wide variety of high-volume SKUs. In addition to this, one of its critical machines frequently stopped, impacting the entire operation.

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Before this project, the team depended on on-site monitoring and manual record-keeping to optimize their processes. While they had records of machine downtime, updating them was time-consuming and often lacked important details. TecnoIndustries needed accurate machine data to make critical decisions and adjustments to ensure continuous improvement.

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The Solution

In December 2020, TecnoIndustries decided to partner with Pulsar to implement its platform at their Santa Catarina plant in Nuevo Leon. Soon after implementation, Pulsar’s real-time data and Pareto charts helped identify the root cause of the key machine’s issues: micro-stops. Machine downtime of less than 5 minutes was often unnoticed by operators but accounted for 80% of downtime in key processes. The main cause was a recurring misalignment in one of the machine components.

After this discovery, TecnoIndustries implemented Pulsar to monitor daily operations across their plants. Armed with precise data, the team took decisive actions to improve operational efficiency across several processes:

• adjusting a critical machine to prevent micro-stops;
• reducing operations from two shifts to one to eliminate downtime; | and
• making critical adjustments to a production line with damaged products

Along with continuous improvement efforts, TecnoIndustries launched a performance bonus program for its workforce, driving focus on efficiency and goal achievement as part of the company culture.

Results

With Pulsar's implementation, the TecnoIndustries team has exceeded key production goals. They've seen a significant boost in efficiency and improved overall profitability.

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These adjustments resulted in a 60% increase in production with only one shift, significantly cutting labor costs. Additionally, they’ve reduced waste by 50% on high-volume products.

While challenges remain in the digitalization of mining and raw material processing, leveraging accurate data in operations has driven a fundamental shift at TecnoIndustries: the workforce now embraces continuous improvement goals and is aligned on how to achieve them.

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Backed with Pulsar's precise operational data, TecnoIndustries is accelerating its growth plan into new markets while fully maximizing its production potential.

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Benefits