The situation
Each machine had a BOM of several hundred items. Purchase worked from emails and memory. Machines regularly waited weeks for one bought-out component, delaying dispatch and the milestone payment linked to it. Nobody could say how far each machine had progressed.
What we put in place
- Machine-wise project with BOM and part status
- Shortage list generated from BOM against stock and open POs
- Stage-wise assembly progress visible to owner and sales
- Milestone billing tracked against project stages
What changes
- Missing parts known weeks earlier
- Customers get real delivery dates
- Milestone payments raised the day a stage is complete
This is a representative case based on situations we commonly see in Indian factories. Company details are withheld and figures are typical ranges. Your results depend on your factory, and we will estimate them with your real numbers.