How Acme Manufacturing cut production delays by 34% with real-time shop-floor tracking
A 500-employee manufacturer replaced spreadsheets and legacy ERP with a custom ERP system, gaining real-time visibility into every work order — and unlocking $4.2M in trapped working capital.
This is an illustrative case study. Company names, identifying details, and testimonials have been changed to protect client confidentiality. The technical solution and target outcomes are representative of the work we do. We extend the same confidentiality to every client.
Where they started
Acme was tracking production on spreadsheets and a 15-year-old ERP that couldn't talk to their inventory system. Work orders took 3 days to process, inventory was a black box, and on-time delivery was stuck at 71%. Expedited freight and rushed rework were bleeding margin — the CFO estimated $1.1M a year in avoidable costs.
What we built
We built a custom ERP system with shop-floor dashboards, IoT machine monitoring, and automated BOM management. The system went live in 6 weeks with zero data migration loss, and replaced five disconnected tools the operations team was juggling.
Target outcomes
More from this project
We went from flying blind to seeing every machine, every order, every part in real time. The ROI was visible in the first month — we freed up over $4M in working capital that was sitting in excess stock.
Representative testimonial — name and role changed to protect client identity.