Industrial intelligence, built by engineers who ship hardware.
Surge Pulse makes production losses visible in real time. Forge Eye brings automated 100% quality verification to the line.
Your hidden capacity is already on the factory floor.
Connect the machines you already own and see output, target vs actual, run / stop / idle / wait states and shift context in real time — then turn recurring downtime into prioritised action.
Pulse Connect
Retrofit machine connectivity from sensors, machine signals, PLCs or external inputs.
Pulse Live
Real-time machine, line and floor visibility with target vs actual and machine state.
Pulse Intelligence
OEE, downtime analysis, bottlenecks, production-loss trends and management summaries.
Pulse Health
Optional vibration and temperature signals for earlier maintenance intervention.
Answers, not more charts.
- Which losses repeat most often?
- Which machines are under-utilised?
- Where do short stops accumulate?
- Which lines or shifts underperform?
- What changed before output dropped?
- What should management act on first?
Pilot on five machines in 30–45 days.
- 01
Pilot & baseline
Up to five machines for 30–45 days. Establish a trusted baseline and quantify hidden production loss.
- 02
Line rollout
Expand to one line or 10–25 machines. Validate downtime, utilisation and shift variance.
- 03
Factory & enterprise
Scale to 50–100+ machines, multiple sites and ERP/MES integration once value is proven.
Buy the field hardware (CAPEX + platform subscription) or run it as Pulse-as-a-Service (OPEX, Surge-owned hardware, maintenance included). Same platform either way.
Automated 100% quality verification on the line.
Forge Eye replaces or augments manual inspection wherever operators measure, compare, verify or reject product by eye.
Where the requirement is deterministic — diameter, position, presence, orientation, print alignment — it uses calibrated machine vision, which is easier to validate. AI is applied only where variation demands it.
Measure
Calibrated measurement of length, diameter, gaps, angles and profiles — replacing gauges and manual sampling.
Surface
Detects cracks, bubbles, flash, contamination and scratches against the approved master.
Verify
Confirms assembly, component presence, position and orientation before product leaves the station.
Pattern
Compares contour, print and pattern alignment to the reference.
Code
Reads and verifies labels, text, barcodes, batch and date codes for traceability.
Continuous
Monitors extrusion and continuous processes, flagging drift before metres of product are rejected.
Built for the lines we know.
PASS → production continues. FAIL → reject or operator alert, with every result recorded for traceability and SPC.
- Rubber & tyres
- Plastic moulding
- Packaging & printing
- Food
- Beverages
- Pharmaceuticals
- Cable & extrusion
- Electronics
- Automotive components
- Ceramics & tiles
- Glass
- Apparel
- Textiles
- Tea
- Personal care
- Metal fabrication
See it on your own line.
Start with a short pilot on a defined production area and get an objective baseline before you commit to rollout.