The Challenge
A mid-sized heavy machinery manufacturer in the UAE was experiencing severe bottlenecks on their shop floor. Their production planning was managed using complex arrays of spreadsheets that were difficult to update and prone to human error.
Tracking multi-level Bills of Materials (BOMs) manually resulted in frequent raw material shortages, delaying the entire assembly line. Additionally, quality control was handled via paper forms, making it impossible to track defects in real-time or isolate faulty component batches.
Our Solution
TABSYST implemented a full-scale ERPNext Manufacturing suite tailored to their specific operational workflows. We digitized their multi-level BOMs into the system, directly linking them to the procurement module to trigger automated material requests based on production orders.
We also configured interactive workstations for supervisors on the shop floor. Using tablets, workers could seamlessly start, pause, and complete operations, logging direct labor hours and material consumption in real-time. We also built customized Quality Inspection workflows that forced mandatory checks before goods could move to finished state.
Key Results
Reduction in Wastage
Faster Production Cycles
Traceability of Batches