How Kineco Achieved Operational Excellence with Shopfloor Performance Tracking Software
Customer Overview
- Industry:
Aerospace Manufacturing - Location: Goa, India
- Challenge:
Production of high-performance composite structures and components
Kineco Limited is one amongst India’s leading innovative companies in the composite industry. The company using advanced processes such as filament winding, autoclave curing, and resin transfer moulding, serving major original equipment manufacturers (OEMs) and Tier-1 suppliers worldwide.
Executive summary
Kineco Aerospace & Defence Composites, a leading aerospace manufacturer in India, improved production performance by implementing shopfloor performance tracking software. This manufacturing software case study shows how real-time KPI tracking replaced manual processes, strengthened accountability, and delivered measurable operational improvements.
By deploying LTS Data Point's digital performance management manufacturing solutions,
Kineco gained real-time production visibility
across shifts, automated Takt time tracking, and established a structured approach to continuous improvement.This transformation enabled leadership to make faster, data-driven decisions while aligning shopfloor execution with broader strategic operational goals.
Transformation at a Glance
- ✓Real time visibility into every work order status
- ✓Automated compliance and audit trails
- ✓Elimination of 90% of data entry tasks
- ✓Synchronised production and quality reporting
The Challenge: Limited Real-Time Production Visibility
Despite having robust operational processes, Kineco faced fundamental visibility challenges that limited their ability to respond quickly to production issues.
Manual Data Collection Creating Delays
Performance data was captured manually during shifts and updated only at intervals on digital displays. As a result, issues surfaced too late for corrective action, forcing supervisors to manage production without "real- time KPI visibility."
No Takt Time Monitoring
Production lines operated without real-time feedback on whether they were meeting planned cycle times. Without a Takt time tracker, bottlenecks were discovered too late, and the true reasons for production delays remained unclear.
Weak Accountability Structures
Without structured systems for tracking issues and assigning corrective actions, responsibility for improvement initiatives was unclear. Follow-through was difficult to monitor, and problems tended to recur.
Inefficient Root Cause Analysis
When problems occurred—quality defects, delivery delays, or production stoppages—the organisation struggled to systematically identify root causes and implement lasting solutions.
As Siddhesh Korgaonkar, Senior Manager – Production at Kineco, explains:
"We needed to move beyond manual tracking. Our teams needed access to real-time data that could drive immediate action and help us maintain our performance standards across Safety, Quality, Cost, Delivery, and People metrics."
Why Digital Transformation Was Critical
The aerospace manufacturing environment is unforgiving. Customer contracts include strict delivery windows, quality requirements, and cost targets. Even small variances can trigger penalties or damage relationships with major clients.
Kineco's leadership recognised that manual performance management wasn't keeping pace with operational complexity. As production volumes increased and customer expectations intensified, the need for a comprehensive aerospace manufacturing KPI system became urgent.
Implementation Details
- ✓
Real-time production visibility solution across all shifts and production areas
- ✓
Automated Takt time tracker to monitor cycle adherence
- ✓
Digital SQCDP dashboard (Safety, Quality, Cost, Delivery, People)
- ✓
Structured action planning with accountability tracking
- ✓
Systematic root cause analysis capabilities
- ✓
Digital SQCDP dashboard (Safety, Quality, Cost, Delivery, People)
The solution needed to work for everyone from operators on the shopfloor to senior leadership. Creating a shared understanding of performance and priorities through effective shopfloor performance tracking software.
Solution Selection: Why LTS Data Point
The Solution: LTS Data Point
LTS Data Point was implemented as a digital shopfloor performance tracking platform to replace manual reporting and create real-time visibility.
- ✓Real-time KPI and Takt time tracking
- ✓Centralised SQCDP dashboards
- ✓Built-in action planning and issue tracking
Kineco evaluated several options before selecting LTS Data Point as their shopfloor performance tracking software. The decision came down to three critical factors:
Purpose-Built for Manufacturing Reality - Data Point was designed specifically for production environments, with features reflecting how manufacturing teams actually work: shift patterns, production lines, operator handovers, and the ability to capture failure reasons at the point of occurrence.
Comprehensive Digital Performance Management - Rather than simply displaying data, Data Point embedded proven continuous improvement practices—balanced scorecard methodology, tiered management structures, action plan discipline, and root cause analysis tools like fishbone diagrams and 5 Whys.
Proven Implementation Methodology - LTS Lean UK offered a phased, collaborative implementation model. Rather than attempting a "big bang" transformation, they worked alongside Kineco to configure the shopfloor performance tracking software to match existing workflows, train users progressively, and build capability over time.
"What stood out was that LTS understood our world" says Korgaonkar.
"They weren't selling us generic software; they were offering an aerospace manufacturing KPI system built around how production operations actually function."
Implementation: Configuring the Digital SQCDP Dashboard
The implementation followed a structured six-week programme focused on three management tiers, ensuring the shopfloor performance tracking software aligned with Kineco's organisational structure:
Enterprise Dashboard
Yearly View
Senior leadership gained visibility across all production areas with year-to-date performance trends, enabling strategic planning and resource allocation.
Enterprise Dashboard
Yearly View
Senior leadership gained visibility across all production areas with year-to-date performance trends, enabling strategic planning and resource allocation.
Management Dashboard
Monthly View
Area managers could filter performance by department, tracking monthly progress and ensuring alignment between operational outcomes and business targets.
Management Dashboard
Monthly View
Area managers could filter performance by department, tracking monthly progress and ensuring alignment between operational outcomes and business targets.
Operational Dashboard
Daily / Weekly View
Team leaders and supervisors accessed real-time performance data by area and shift, with immediate visibility of issues requiring attention through the digital SQCDP dashboard.
Operational Dashboard
Daily / Weekly View
Team leaders and supervisors accessed real-time performance data by area and shift, with immediate visibility of issues requiring attention through the digital SQCDP dashboard.
Core Capabilities Configured
Customised KPI Framework
The aerospace manufacturing KPI system was configured to track Kineco's specific Safety, Quality, Cost, Delivery, and Lean metrics, with visual indicators (green/red traffic lights) showing at-a-glance status against targets.
Automated Takt Time Monitoring
Each production line received a digital Takt time tracker. When production fell behind schedule, the system automatically prompted operators to record the reason for delay—creating an immediate, timestamped record of issues as they occurred.
Integrated Action Planning
Whenever a KPI showed variance or a production delay was recorded, team leaders could generate an action plan directly from the dashboard. Actions were assigned to specific individuals with due dates and tracked through to completion.
Pareto Analysis and Trend Visualisation
The shopfloor performance tracking software automatically generated Pareto charts showing the most frequent failure reasons, helping teams focus improvement efforts where they would have the greatest impact.
Shift Handover Continuity
All data, action plans, and performance status remained visible across shift changes, ensuring continuity of awareness and reducing the risk of issues being overlooked.
Onboarding Highlights
LTS worked closely with Kineco's operations team to ensure the real-time KPI tracking system reflected actual working practices:
Process Mapping - Production workflows were documented and configured into the shopfloor performance tracking software, including all workstations, shift patterns, and handover procedures.
Operator-Friendly Data Capture - Input forms were designed to be simple and quick, minimising the time operators spent on data entry whilst ensuring accurate, consistent information in the digital SQCDP dashboard.
Phased Training - Training was delivered in stages starting with team leaders, then supervisors, then operators for new aerospace manufacturing KPI system.
Ongoing Refinement - The initial six-week implementation phase included regular review sessions where feedback was gathered and the system was adjusted to better fit Kineco's needs.
The result was a real-time production visibility solution that felt natural to use—not a burden imposed on teams, but a tool that genuinely helped them perform their jobs more effectively.
Results: Measurable Impact from Shopfloor Performance Tracking Software
100%
Real-Time Control
Eliminated Reporting Delays Across Production Lines
25%
Takt Adherence
Improved Plan vs Actual through Live Alerts
Enhanced
Accountability
Clear ownership and follow-through on shopfloor actions
Data-Driven
Decisions
Root cause analysis reduced from days to minutes
Within months of deploying their shopfloor performance tracking software, Kineco began seeing tangible operational benefits:
Real-Time Operational Control
The immediacy of visibility through the real-time KPI tracking system transformed how teams responded to issues. Problems that previously went unnoticed for hours were now flagged instantly, enabling swift corrective action.
Improved Takt Time Adherence
The automated Takt time tracker provided immediate feedback when production fell behind schedule. Operators recorded delay reasons in real time, creating a database of production constraints that informed continuous improvement initiatives.
Enhanced Accountability and Collaboration
Cross-functional teams now had a shared platform within the digital SQCDP dashboard for collaboration. Rather than scattered email threads and verbal updates, all improvement activity was documented, visible, and trackable in one place.
Data-Driven Decision Making
The Team Leader Dashboard became particularly valuable, quickly highlighting underperforming sections and specific gaps. This digital performance management approach focused leadership attention where it was most needed.
Bottom-Up Operational Engagement
Perhaps most importantly, the aerospace manufacturing KPI system created a sense of shared ownership across the organisation.
Key Takeaways for Manufacturing Leaders
When evaluating shopfloor performance tracking software:
- ✓Start with real-time visibility
- ✓Ensure comprehensive coverage
- ✓Implement Takt time monitoring
- ✓Build for all user levels
- ✓Choose aerospace-grade reliability
- ✓Embed improvement methodology
- ✓Expect measurable ROI
- ✓Enable structured shift handovers
Ready to transform your production operations with shopfloor performance tracking software?
Discover how LTS Data Point can bring real-time visibility, structured improvement, and measurable results to your manufacturing operations.
What This Meant for Kineco
“ By providing a central location to input, analyse and share our KPI’s , “Data Point” is enabling the Site management to more easily focus their efforts, as a team, on the whole of the business. It’s ability to allow automated data entry and analysis of trends, is giving us more time to spend on improvement, rather than just reporting the numbers. Combined with a disciplined approach to its use, within our SQDC meeting process, I believe “Data Point” will enable us to continually focus on key issues and drive business Excellence in all areas.”
Siddhesh Korgaonkar
Senior Manager-Production