ProdFlow Manufacturing Platform
An internal operations platform built for a Romanian manufacturing company with 150 employees. The system covers production scheduling, inventory management, quality control, and real-time shop floor monitoring.
The Challenge
The client's production planning was done in Excel, quality control was paper-based, and inventory counts were performed manually once a month — leading to frequent production stoppages when materials unexpectedly ran out. The disconnect between the shop floor and the management office meant that production delays were discovered only when deadlines were missed, not when they started.
Our Approach
Built a production scheduling system that takes customer orders, breaks them into manufacturing steps, allocates resources (machines, operators, materials), and generates optimised daily production plans
Developed a real-time shop floor dashboard using IoT sensors on key machines — tracking cycle times, downtime, and output counts automatically without manual data entry
Implemented a digital quality control module replacing paper checklists — operators log inspections on tablets, non-conformances trigger automatic alerts, and all quality data is traceable to the specific batch and operator
Built an inventory management system with automatic reorder points, supplier lead time tracking, and BOM (Bill of Materials) explosion — ensuring materials are ordered before they run out
Created a management dashboard showing real-time OEE (Overall Equipment Effectiveness), production progress vs plan, and quality metrics
Integrated with the client's existing accounting system via API for seamless financial reporting
Results
Production stoppages due to material shortages dropped from 8 per month to near-zero
Quality non-conformance rate reduced by 42% through real-time detection and traceability
Production planning time reduced from 2 days per week to 3 hours with automated scheduling
Management gained real-time visibility into shop floor operations for the first time in the company's history
ROI achieved within 7 months of full deployment
Technologies Used
“This platform transformed how we operate. For the first time, I can see exactly what's happening on the shop floor from my desk — in real time.”
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