Manufacturing Sector

In the manufacturing sector, efficiency, traceability, and cost control are the most critical issues. Digitally tracking every step, from the production line to the warehouse, and from procurement to shipment, reduces waste rates and increases capacity utilization. This example illustrates the operational challenges faced by a mid-sized manufacturing firm and its solution process.

Client Profile

Mid-sized industrial manufacturing firm. 80 employees, 3 production lines, 200+ orders per month capacity.

Challenges Faced

• Lack of Production Tracking: It was unknown which order was at which stage. Delivery dates could not be provided to customers, and delays became routine.
• Waste and Loss: Waste rates were high because raw material consumption was not tracked. Actual production costs could not be calculated.
• Planning Difficulty: Production plans were made using Excel and whiteboards. Machine breakdowns and material shortages emerged as surprises.

Solution Approach: Production Management System

• Real-Time Production Tracking: Recording the start, process, and completion steps of each work order using barcodes or tablets.
• Material Requirements Planning: Automatic raw material needs calculation and procurement alerts based on order status.
• Cost Analysis: Instant tracking of labor, material, and energy costs for each product. Identification of profitable and unprofitable products.

Results Achieved

• On-time delivery rate for orders increased by 35%
• Raw material waste rates decreased by 40%
• Production planning time decreased from 2 hours to 20 minutes daily
• Actual product costs became visible for the first time