Case Study - Cable Manufacturing

Client Overview

A specialized cable manufacturer producing custom-made cables to fulfill customer orders, with complex production and material tracking needs.

Challenges

The client’s production workflow was manually handled, leading to several operational pain points:

• Manual job orders for each customer order, prone to errors.
• Time-consuming conversion of job orders into production orders with detailed material lists.
• Lack of real-time material reservation for production.
• Manual updates to inventory after production completion.
• Difficulties in accurately calculating material costs and profit per order.
• These manual processes caused delays, data inconsistencies, and reduced visibility into production performance and profitability.

Solution

We developed a Production & Inventory Management System customized for the client’s manufacturing process, including:

• Automated job-to-production order conversion with all material details
• Real-time material reservation against production orders.
• Automated inventory deductions upon production completion.
• Cost calculation modules to track material usage and compute per-order profitability.
• Reports for management to monitor production efficiency, costs, and margins.

Results

• Streamlined production workflow with reduced manual effort.
• Accurate material tracking across orders and inventory.
• Clear visibility into production costs and order profitability.
• Improved decision-making with real-time data and reporting.
• Higher operational efficiency and reduced risk of stockouts or delays.