Manufacturing Firm Reduces Production Downtime by 40%
A precision engineering company streamlined their shop floor operations and gained real-time visibility into production, dramatically reducing downtime and improving inventory management.
40%
Less downtime
25%
Inventory reduction
3x
Faster reporting
Client Background
This precision engineering manufacturer produces custom components for the aerospace, automotive, and mining industries. Operating a 15,000 sqm facility with multiple CNC machining centers, they employ 85 staff and run 24/7 operations. Their growth had outpaced their existing systems, creating visibility gaps and inefficiencies in production planning.
The Challenges
Before implementing the solution, the client faced several critical business challenges
Production scheduling done manually on whiteboards and spreadsheets
No real-time visibility into job status or machine utilization
Excess raw material inventory tying up working capital
Frequent production delays due to material shortages
Disconnected quality control processes
Manual time and attendance affecting labor costing accuracy
Our Solution
We deployed SAP Business One integrated with BEAS Manufacturing to create a unified shop floor management system. The solution connects production planning, material management, quality control, and financial reporting into a single platform with real-time dashboards.
Key Components
- SAP Business One for core ERP and financials
- BEAS Manufacturing for production planning and control
- Shop floor data collection terminals at each work center
- Real-time production dashboards for management
- Integrated quality management with test protocols
- Machine integration for automated production logging
The Results
The integrated manufacturing solution delivered measurable improvements across production efficiency, inventory management, and reporting capabilities.
Unplanned downtime reduced by 40% through better scheduling
Raw material inventory reduced by 25% with MRP optimization
Real-time visibility into production status for all jobs
Labor cost accuracy improved with automated time capture
Quality data integrated with production records
Management reports generated in minutes instead of hours
"The visibility we now have into our shop floor is incredible. We can see exactly where every job is and identify bottlenecks before they cause delays. Our customers are getting better lead times and we're more profitable."
Managing Director
Precision Engineering Manufacturer
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