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A system for make-to-order manufacturing

A Slovak metalworking company — sheet-metal processing (CNC cutting, bending, welding, machining)

A system tailored to the company’s real technological operations that carries an order from the quote, through shop-floor production reporting, to the profitability of every single order.

Challenge

The previous software did not match the real production processes, and the company had no visibility of the true costs and profitability of individual orders.

Solution

Our team built a system that covers the whole flow — quote → order → production plan → reporting on shop-floor terminals (RFID) → dispatch → profitability evaluation. The operation catalogue is tailored to metalworking; the real time spent on operations is measured directly on the shop floor.

Results:

• The whole make-to-order flow in one system — from quote to profitability
• About 2,700 orders a year, about 50 users
• Production reporting on shop-floor terminals with RFID operator identification
• Automatic calculation of cost and profitability of each order (revenue from accounting)
• The system is still in use today

Built for real metalworking

The routings match the company’s actual operations — laser cutting, bending, welding, CNC machining, surface finishing, quality control, assembly. Every operation has an order, a planned date and a status, so the foreman and sales both see exactly where an order stands. It is not a generic ERP compromise, but a system built around that shop’s processes.

Real time and real profitability

An operator identifies at the terminal with an RFID card and starts/stops work on an operation — so the system records the real time worked on a specific order, not an estimate. Profitability is calculated automatically: cost (material, labour, sub-supplies, transport) against revenue from accounting. The company can see which orders actually make money.