Flow mapping
On-site work to reconstruct the real path of orders, materials and production, including the exceptions handled verbally.
All case studies
Case study · Manufacturing
From spreadsheets to a single control room for production and inventory.
A Sicilian manufacturer ran orders, materials and production progress across dozens of parallel spreadsheets. We built the system that now holds everything together.
At a glance
- Client
- Manufacturer, ~80 employees
- Sector
- Contract manufacturing
- Duration
- 5 months + ongoing management
- Services
- Custom software, integration, maintenance
The challenge
Correct data, scattered everywhere and never aligned.
Every department had its own spreadsheet: orders in one, materials in another, production progress in a third. The information existed, but no one saw the same number at the same time.
The result was double entry, evening reconciliations and decisions made on stock and lead times already days old. A single absence could freeze an entire chain of data.
Our solution
A single source of truth, built on their real flow.
Instead of imposing off-the-shelf software, we mapped the real flow from order to shipment and built a system that mirrors it, with per-department permissions and one shared master data set.
Custom platform
Web application with master data, orders, bills of materials and production progress, accessible from the office and shop-floor stations.
Integration and inventory
Sync with the existing accounting system and automatic stock deduction on consumption, with no more double entry.
Rollout and support
Historical data migration, on-the-job training and continuous support through the first weeks of operation.
The results
Less manual work, decisions on today's data.
-40%
time on manual entry
0
evening reconciliations
real-time
order and inventory status
Production plans on stock updated to the minute and the sales office commits to reliable delivery dates. Know-how no longer lives in people's heads but in the system, and every evolution starts from solid, documented foundations.
“For the first time, the office and the shop floor look at the same numbers. We no longer chase data: we use it.”
Technologies
Tools chosen to last and integrate.
- Next.js
- Node.js
- PostgreSQL
- REST APIs
- Accounting integration
- Managed hosting
A similar case?
Do your processes also live on too many spreadsheets?
If rebuilding a single source of truth would save you hours every day, let's start from a concrete mapping of your flow.