How It Works

FactoryPulse is built in partnership with Factbird. Factbird's manufacturing intelligence platform — sensors, hardware and cloud — owns the machine monitoring; FactoryPulse owns exactly one job — providing the connection with NetSuite.

FactoryPulse maps NetSuite work centers to monitored production lines, and each line to its counting sensor. A routing can mix both kinds of operation — that is the point:

Seq	Operation	Work center	Captured by
10	Cook & Season	Cook Kettle	NetSuite / MES
20	Form & Portion	Forming	NetSuite / MES
30	Bag & Seal	Bagging Line	FactoryPulse (case counter)
40	Case Pack & Palletise	Case Pack	NetSuite / MES

On release, the connector resolves which operation is sensor-mapped and creates the batch on that line. When the operator ends the batch, the completion posts measured machine time on that operation only. Unsensored operations remain ordinary shop-floor work.

Safety posture

• Quantity ownership is configurable — in MES-owned mode, completions are time-only — with no quantity posted — safe alongside lot- and serial-controlled processes.
• Nothing is invented — no labor, no consumption, no serial numbers. What the sensor measured is what lands.
• Every write is idempotent — replays and retries converge instead of duplicating.

Feature — Release → Batch on the Line

Release a work order in NetSuite and FactoryPulse automatically creates the matching batch on the monitored Factbird line — the work order number becomes the batch number, the NetSuite item becomes the product. No re-keying, no waiting, no second system for the office to maintain.

All screenshots are unedited captures from live systems — a NetSuite account and a Factbird-monitored line with a real photoelectric sensor.

How it works in NetSuite

1. Start from a completely standard work order

Planned, routed, nothing special — your planners change nothing about how they work:

The monitored line's batch list at the same moment — the work order does not exist there yet:

2. Release it — that is the only human action

FactoryPulse resolves which routing operation is sensor-mapped and creates the batch on that line, with the planned quantity carried over. The join is natural — batch number = work order number, product = NetSuite item — so there is no cross-reference table to maintain, and none to drift. And because only the sensor-mapped work center is touched, every other operation stays ordinary NetSuite/MES work:

Back on the work order, a FactoryPulse panel shows the batch state, the sync flag and the exact mapping in plain sight — so the office can see the shop-floor link without leaving NetSuite:

3. The operator starts the line as usual

The batch goes green in Factbird's own operator view. Nothing changes for people: planners release as they always did, operators run the line as they always did — nobody re-keys a work order number into a second system, so that whole class of transcription error simply disappears:

Feature — Sensor Counts → Completion

While the line runs, Factbird's sensor counts every piece. When the batch ends, FactoryPulse posts the completion in NetSuite automatically — carrying the measured machine time onto exactly the operation that ran. Your costing gets real machine time from the sensor clock instead of estimates, and nothing depends on someone remembering to key results in at the end of a shift.

How it works in NetSuite

1. The line at work

The live view during a run — the blue trace is the real sensor, running around 1,400 pieces a minute against the product's expected and validated speed thresholds (the same speeds every OEE figure is judged against):

2. The run ends — and NetSuite already knows

Result of this 3-minute run: 3,503 produced · 3,503 good · 0 stops. Both batch events reached NetSuite by webhook within seconds, and a scheduled reconciler sweeps up anything a webhook could ever miss — so a busy network or a missed event never means lost production data.

3. What lands back in NetSuite

A completion posts automatically, its memo carrying full provenance — which batch, which line, which event — so every number is auditable back to its source:

The operations table is the heart of the design — machine run time on the sensor-mapped operation only, with every labor and setup column zero. Nothing is invented: no labor, no consumption, no quantities your MES didn't authorize. In MES-owned mode the completion is time-only — with no quantity posted — which makes it safe alongside lot- and serial-controlled processes:

4. The join, side by side

The NetSuite work order lives in Factbird's batch list beside the plant's own batches — one shared identity, visible to both the office and the floor:

Machine OEE Dashboard — inside NetSuite

Every monitored line on one page, rendered inside NetSuite itself: per-machine OEE, run time, produced counts, stops, and sensor health — filterable by period, machine and work center.

And the detail that matters on a real shop floor — a sensor that stopped reporting months ago shows OFFLINE, and the downtime Pareto names the causes (Capper, Start-up Time, Item Changeover…):

Why “honest OEE” matters

OEE divides by the product’s nominal speed. If that speed is wrong, OEE silently becomes fiction — we have seen a mis-seeded speed produce a 1,170,808% OEE. FactoryPulse gates every reading through a plausibility check, shows how many were excluded, and never averages a bad reading into a headline number.

Frequently Asked Questions

What is Consule's relationship with Factbird?

FactoryPulse is offered in partnership with Factbird. The manufacturing intelligence solution — the sensors, the gateway hardware and the AI-powered cloud platform — is Factbird's product. What Consule Solutions provides is the connection with NetSuite: a native SuiteScript connector that moves Factbird's live machine data into your ERP. You use Factbird for the machine monitoring and FactoryPulse for the NetSuite side.

Which sensor platforms does FactoryPulse support?

FactoryPulse ships with a native connector for Factbird cloud (GraphQL). The mapping layer — work center → line → sensor — is platform-agnostic by design.

Do all my work centers need sensors?

No — and that is the core design decision. Only sensor-equipped work centers are mapped. Everything else stays ordinary NetSuite/MES work that your shop floor completes as usual.

Will it fight with my MES or lot control?

No. In MES-owned quantity mode FactoryPulse posts time-only completions: measured machine minutes on the operation that ran, nothing else. Lot and serial processes keep full ownership of quantity.

What happens if a webhook is missed or a sensor dies?

A scheduled reconciler sweeps the lines and stages anything a webhook missed, and a watchdog flags any sensor that stops reporting as OFFLINE — visibly, on the dashboard.

Is this middleware?

No. FactoryPulse is native SuiteScript inside your NetSuite account, talking directly to the sensor cloud. No middleware, no external servers holding your data.

How do I get it?

Contact Consule Solutions for a live demonstration on your own lines.