Metal and Sheet Processing

In the metal sheet processing and machining sector, production precision, work order tracking, and accurate cost calculation are critically important. Workshops managed with manual processes suffer from reduced capacity utilization and inaccurate cost estimates for bids. This case study summarizes the digital transformation journey of a medium-sized manufacturing firm.

Customer Profile

A manufacturing company operating CNC machines and sheet metal processing equipment. 35 employees, 10+ machines, order-based production.

Challenges Faced

• Lack of Work Order Tracking: Data such as which job was running on which machine and for how long was not collected.
• Unknown Actual Costs: Bid prices were based on experience. It was unclear which jobs were profitable and which were loss-making, even after project completion.
• Difficulty in Quality Tracking: Customer requirements and tolerance information remained on paper and were lost during production.

Solution Approach: Manufacturing Management System

• Digital Work Orders: Automatic generation of work orders for each order. Operations, durations, and machine assignments within a single system.
• Real-Time Cost Tracking: Instant calculation of material, labor, and machine costs for each work order.
• Quality Control Module: Customer specifications and tolerance information in a digital environment, with automated control points during production.

Results Achieved

• Bid accuracy increased by 40%
• Machine utilization rate rose by 20%
• Quality-related return rates decreased by 55%
• Cost deviation per work order reduced by 35%