SOLUTIONS
Real-Time Production Visibility
See what your lines are doing while you can still do something about it. XL turns machine signals into accurate live production data, and ACI turns that data into daily improvement on the floor.
The visibility gap
Most plants find out too late
By the time a shift report reaches a supervisor, the shift is over. The line that ran slow for three hours cannot be recovered, and nobody can say with certainty why. Data that arrives after the fact explains history — it does not change outcomes.
Reconstructed losses
Downtime is recalled from memory at the end of the day, not recorded as it happens.
Invisible small stops
Short stoppages never reach a log sheet, yet together they often outweigh the big failures.
Competing numbers
Two departments arrive at the same meeting with two different versions of the truth.
Misplaced effort
Improvement work goes to the loudest problem instead of the most expensive one.
On the line
The number is above the machine
The scoreboard shows target against actual while the shift is still running. No login, no report, no waiting. An operator glances up and knows whether the line is winning or losing — and a supervisor walking the floor knows it at the same moment.
- Rate, target and efficiency updated continuously
- Andon colour change the second a process stops
- Readable across the full length of the line
XL scoreboard above a production line
In the office
One set of numbers, every level
The same data the operator sees is the data in the daily meeting and the monthly review. Nobody rebuilds it in a spreadsheet, nobody argues about whose figure is right, and the discussion moves straight to what to do about it.
- Built-in OEE, downtime, changeover and top-loss reports
- Accessible in a browser — nothing to install
- Export to Excel when you need to go deeper
XL reporting dashboard on a laptop
How it works
What real time actually means
Three things have to be in place. Miss one and the system becomes decoration.
Capture
A sensor on the existing machine feeds XL directly. Every cycle, stop and changeover is timed to the millisecond — no operator paperwork, no interpretation.
See
The scoreboard above the line shows target against actual, right now. Managers open the same figures in a browser. One source of truth at every level.
Act
Visibility only pays when behaviour changes. ACI coaches the routines, reason codes and daily meetings that turn a live number into a decision.
Sensor mounted on machine
Operator scanning a reason code
Daily improvement meeting
Where ACI comes in
Data alone does not improve production
A monitoring system installed without a working routine around it becomes wallpaper within a month. This is the part we care about most.
- Reason-code structure your operators will actually use
- First daily meetings run alongside your supervisors
- Training so the team can read what it is looking at
Install the system. Then build the habit.
ACI has coached continuous improvement since 1997. We stay involved after installation, because the gain comes from what your team does with the number — not from the number itself.
Start with a Performance Audit to see where you stand, or go straight to Consulting & Training.
Same data, three jobs
Three horizons, one set of numbers
That is what keeps a plant aligned instead of arguing.
This shift
Operators need two answers: what must we make, and are we on track. The scoreboard answers both without anyone asking. Win the Shift
This week
Supervisors work patterns rather than incidents — a recurring stop, a slow part, a changeover that always overruns. Reduce Downtime
This month
Leadership ranks losses by hours lost and directs resources where the return is largest. Improve Productivity
Trusted across manufacturing
Proven across industries
Real-time visibility applies to any discrete or batch process.
Start here
See your real numbers
Most teams are surprised by their true downtime in the first week. Try it on one line and judge the result yourself.