Client 

Client 

Small and mid-sized manufacturers who needed practical quality accountability without heavy bureaucracy.

The challenge 

Many SMEs either have no non-conformance process, or they have a process that is too complex to maintain. The result is repeat issues and a familiar pattern: “We had this problem before. What did we do last time?” 

What we did 

We implemented a lightweight non-conformance and corrective action workflow that teams could actually sustain. Depending on the environment: 

• In some systems, the native quality app was used for logging 

• In other cases, a controlled Excel-based log was implemented where it was the most practical option 

What ‘good enough’ looked like 

• Basic logging of issues 

• Tracking of resolutions 

• Clear accountability through assigned owners and follow-up 

Results 

• Clearer accountability 

• Faster containment and resolution 

• Reduced repeat issues because previous actions were visible and searchable 

Why it matters 

A simple quality workflow that gets used beats a perfect workflow that gets ignored. The goal is not paperwork. The goal is learning and repeatability. 

Client 

Manufacturing businesses that needed realistic capacity planning and better labour utilisation. 

The challenge 

When run times, setup times, and work centre capacity are not defined properly, schedules become optimistic and delivery promises become unreliable. Teams compensate with overtime and constant rescheduling. 

What we did 

We implemented routing and work centre data that reflected real work. 

This included: 

• Defining run times and setup times 

• Using motion studies to validate time assumptions What became visible Once routing data was realistic, it became clear that some tasks could be split into two linked activities: 

• A higher-skilled portion of the work 

• A lower-skilled portion of the work This maintained one-piece flow while allowing higher-skilled workers to focus their energy where it created the most value. 

Results 

• Higher output with less overtime

 • Reduced bottlenecks because labour allocation matched the true constraint 

Why it matters 

Capacity planning is only as good as the data behind it. When routing and work centre assumptions match reality, scheduling becomes a practical tool instead of a constant negotiation. 

Client 

Manufacturing businesses using ERP systems to manage product data and production execution. 

The challenge 

Bills of Materials (BoMs) and work instructions often drift apart. For example, the BoM might specify one quantity or component, while the instruction on the floor specifies something different. When instructions are unclear or incomplete, teams compensate with workarounds. 

That creates: 

• Production errors and rework 

• Inventory discrepancies that are difficult to explain 

• Unreliable product costing What we did We cleaned up BoMs and aligned them with clear, complete production instructions. 

How we controlled changes 

We implemented a product lifecycle management approach: 

• BoMs and instructions were maintained through product management, not informally on the floor 

• Sign-offs and approvals were required from relevant parties before changes went live 

Results 

• Increased inventory accuracy 

• Fewer questions and less time spent investigating discrepancies 

• More accurate costing because consumption and structure were consistent 

Why it matters 

BoM accuracy is foundational. When BoMs and instructions match the real process, everything downstream improves, including purchasing, planning, inventory, and margin visibility. 

Client 

Manufacturing businesses using Odoo, Zoho, and Pronto. 

The challenge 

Spreadsheet-based production scheduling often fails in the same ways: 

• Information becomes outdated quickly 

• Version control breaks down 

• The schedule depends on a subject matter expert to keep it alive 

• When that person is absent, the shopfloor loses direction In some cases, maintaining the spreadsheet required up to 6 hours per day of admin effort. 

What we did 

We replaced spreadsheet scheduling with system-based workflows that created live visibility and clear priorities. 

Examples across systems: 

• Odoo: Used standard manufacturing functionality and introduced priority rules for manufacturing orders based on whether they were required for delivery orders or stock orders. Stock orders were prioritised based on inventory levels. 

• Zoho: Built a custom planning tool in Zoho Creator, including a planning algorithm to handle complex manufacturing flows and constraints such as tool and space limitations. 

• Pronto: Implemented a custom prioritization algorithm for delivery orders based on destination state. 

Results 

• Shopfloor staff could work more autonomously because priorities were visible and current 

• Live tracking of orders through manufacturing improved day-to-day coordination 

• Admin time dropped significantly because planning focused on exceptions rather than manually maintaining every detail 

Why it matters 

The biggest gain from “moving off spreadsheets” is not technology. It is operational resilience. When priorities are visible and current, production can keep moving without bottlenecks around a single planner.