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Case studies

Measurable outcomes, repeatable patterns

Examples of digitization, ERP–shopfloor integration, error-proofing, and inventory systems with clear results.

Spare Parts Store Digitisation

Industrial manufacturing•
Outcome
60–70% faster GRR → dispatch material movement
Problem

Manual packing and dispatch verification caused delays, data inconsistencies, and compliance risk at high throughput.

Solution implemented
SCMOPSAIDCCompliance labeling
Results
60–70%
Faster GRR → dispatch movement
↓
Lower manual verification effort
↑
Higher dispatch accuracy
Before vs After
BEFORE
  • Paper/manual checks at packing
  • Delayed ERP updates
  • Limited traceability on shipment units
AFTER
  • Scan-verified packing workflow
  • Real-time ERP interfacing
  • QR traceability + compliant labels
Compliance workflowERP interfaceQR traceability

Assembly Line Digitisation

Assembly operations•
Outcome
~20% recovery of lost production capacity
Problem

Spreadsheet-based reporting hid downtime drivers and slowed corrective actions across shifts.

Solution implemented
MFGOPSERP integrationIoT/PLC data capture
Results
~20%
Recovered production capacity
↓
Unplanned downtime
↑
First-pass yield
Before vs After
BEFORE
  • Manual downtime logs
  • Delayed KPI visibility
  • Inconsistent production data
AFTER
  • Real-time downtime capture
  • Automated ERP transactions
  • Shift-ready dashboards and alerts
Downtime captureQuality monitoringERP automation

Lean Inventory Management & JIT

Supply chain•
Outcome
25–30% inventory reduction with stable output
Problem

Excess line-side stock increased handling, space usage, and planning noise, without improving output stability.

Solution implemented
SCMOPSJIT workflowsInventory visibility
Results
25–30%
Inventory reduction
↑
Replenishment predictability
↑
Inventory turns
Before vs After
BEFORE
  • Overstocked line-side areas
  • Reactive replenishment
  • Low visibility on consumption signals
AFTER
  • Consumption-driven controls
  • JIT replenishment loops
  • Real-time inventory dashboards
Consumption-drivenJIT replenishmentInventory turns

Kitting, Sequencing & Poka‑Yoke

Line-side feeding•
Outcome
Near‑zero picking and kitting errors
Problem

Incorrect kits and sequence breaks caused frequent line stops, rework, and high dependence on supervision.

Solution implemented
SCMOPSPoka‑Yoke SystemsPick‑to‑Light
Results
≈0
Picking & kitting errors
↓
Line stoppages
↑
Takt time stability
Before vs After
BEFORE
  • Manual kit checks
  • Frequent sequence breaks
  • High supervision dependency
AFTER
  • Error-proof kitting validation
  • Sequence-controlled feeding
  • Predictable line-side execution
Error proofingTakt stabilityLower supervision
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