Falco HVM

High-Volume Manufacturers (HVMs) operate in a world of relentless pace and precision. When you're managing hundreds or thousands of SKUs, even a minor disruption can snowball into missed shipments, dissatisfied customers, and production chaos. And yet, most manufacturing systems today — whether ERP, MES, or legacy add-ons — don’t give HVMs the real-time responsiveness they need. That’s where Falco OPS steps in.

The HVM Problem: Too Much Complexity, Too Little Control

Most HVMs struggle with the same operational friction.

• Preventive Maintenance is reactive at best — maintenance data is scattered or manually logged
• Dashboards are fragmented and lagging — different departments track performance on disconnected Excel sheets
• Production planners rely on best guesses — they lack constraint-based simulation to optimize shift-level plans
• Floor-level data is either missing or delayed — IoT deployments are expensive, bulky, or not tailored for your use case
• Teams waste time reconciling data instead of making decisions — too much energy goes into compiling reports, not acting on them

All this while every hour of downtime eats into your bottom line

What Falco OPS Enables for HVMs

• Zero Surprise Breakdowns: TPM-driven preventive maintenance built on real field data — not guesswork
• One View of Performance: Shift-wise MyKRA dashboards give every department, line manager, and CXO instant visibility
• IoT Without the Drama: Falco DOIT (Device Operations + IoT) gives you real-time machine data via plug-and-play edge devices. No huge setup cost or vendor lock-in
• Plan Smarter, Not Just Harder: Capacity Planning that considers real-world constraints like man-machine availability, production changeovers, and inventory buffers
• Integrated Issue Resolution: MyAssist lets users raise tickets, track delays, and escalate problems within one platform — reducing finger-pointing and slippages

From Chaos to Clarity: Real HVM Scenarios

Imagine a production supervisor walking in for the morning shift and seeing:

• A shift dashboard showing yesterday’s top 3 underperforming KPIs
• Pending maintenance alerts for 2 machines on his line
• A prioritized list of raw material consumption and replenishment tickets
• A visual simulation of today’s shift plan with live resource constraints

All this, without switching tools or chasing spreadsheets.
That’s what Falco OPS delivers.

What Makes Falco Different?

Falco ECM isn’t just theory — it’s been deployed in real high-mix, high-compliance operations. And the results are powerful:

• Purpose-Built for HVMs: We understand batch sizes, line balancing, machine dependencies, and pressure on delivery timelines
• Modular, Not Monolithic: Start with TPM or DOIT or Planning — scale up as needed
• Plug-and-Play IoT: Our hardware is compact, affordable, and built for rugged environments
• Human-Centered Interfaces: Dashboards, alerts, and reports are designed for action, not just display.
• Fast Time to Value: No multi-year deployments. Most modules go live in weeks

Bringing Discipline Without Slowing You Down

Falco OPS doesn’t just automate. It disciplines

• Ensures maintenance isn’t skipped
• Flags process delays before they snowball
• Makes every team accountable with role-specific dashboards
• Allows planners to simulate alternate capacity allocations in real time

This is manufacturing execution without the rigidity of traditional MES or the baggage of legacy ERP customizations.