Production Planning & Reporting Software Modernization
For a US-based Flexible Intermediate Bulk Container (FIBC) manufacturer
About
The customer’s existing MS Excel-based reporting system was not able to provide the required insights for production planning, leading to increased costs. They needed a unified solution to effectively monitor machinery, human resources, stocks, and orders.
Capablity
Enterprise Software
Industry
Manufacturing
Country
USA
Key Features
The reporting system helped the manufacturing company track and measure production against the set goal, ensuring better planning and optimum plant capability & resource utilization.
Reporting automation
Offers interactive & intuitive reports, analytical reports, charts, graphs, etc., for all production process stages, including raw material expenses, labor costs, etc.
Inventory management
Visibility into material flow across departments – from the warehouse to the production line to avoid overstocking & understocking.
Intuitive dashboard
Unified platform to effectively track the entire production process, from inventory to production & planning to report, with a process-controlled mechanism.
Order projection & mapping
Reporting system helps with demand forecasting by mapping the projected orders and inventory levels.
Challenges
- Very high production cost due to no insight on materials required and used
- Manual MS Excel style reporting process
- Lack of business visibility in terms of production, inventory, and sales plan
- Difficulty in resource/labor allocation across the entire production process
Solution
Our team revamped the Production Planning and Reporting Software to help enable tracking & management of daily production processes, production estimation planning, and streamlining of related processes. The modernization initiative was divided into various phases – from upgrade & integration for accurate tracking & measurement, to improving the application’s interface.
System Upgrade
Our team utilized Microsoft.NET to develop a scalable platform for production planning & reporting. We utilized ASP.NET GridView for easy insertion, deletion, sorting, and paging of record items.
Real-time reporting mechanism
We developed a custom reporting engine component that generates real-time production reports with a custom drag & drop option in Gantt style or interactive scheduling mode based on KPIs and metrics.
Planning & integrations
We designed planning modules to map the client’s production cycle. Our specialist team integrated the developed application with the client’s existing Microsoft Dynamics GP 2010 database. This enabled seamless data extraction & sharing between ERP, accounting, HR, supply chain management & other applications.
User-friendly interface
As the client’s staff was used to Microsoft Excel for performing daily tasks, we designed the interface to keep the look & feel intact and ease up the user experience of the modernized software. We utilized .Net Charts and Bootstrap for UI. Our team has an in-depth understanding & exposure to using Chart Helper to export report data into MS Excel or PDF or share it via email.
Technologies Used
Project Snapshots
50%
reduction in production cost
100%
data accuracy with automated data collection
30%
increase in inventory management efficiency
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