Highlights
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50+ CNC & VMC machines digitised
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Real-time production planning and scheduling using Plan vs Production dashboards
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Mobile app for frontline operators to record production counts, rejections, and downtime
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OEE dashboards providing visibility into machine availability, performance, and quality
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Seamless Tally integration with zero disruption to existing finance workflows
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Improved visibility, accuracy, and decision-making across planning, operations, and accounting
About the Client
The client is a well-established precision machining manufacturer based in Uttarakhand, supplying high-accuracy components to automotive customers.
The shop floor operates more than 50 CNC and VMC machines in a high-volume, precision-critical environment. Operations demand strict schedule adherence, tight quality control, and accurate financial tracking.
Before adopting ManufApp, many planning, production, and reporting activities were handled manually, which limited real-time visibility and slowed down decision-making.
Challenges
Before implementing ManufApp, the organization faced several operational hurdles.
Planning & Scheduling Gaps
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Production planning relied heavily on spreadsheets and manual methods
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No live visibility into planned vs actual output on a daily basis
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Difficulty rescheduling jobs dynamically during machine breakdowns or delays
Manual Shop-Floor Recording
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Operators recorded production, rejections, and downtime on paper or local logs
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Data delays and inconsistencies were common
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Supervisors lacked real-time visibility into shop-floor performance
Lack of OEE Visibility
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No consolidated, real-time view of CNC/VMC utilization
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Availability, performance, and quality losses were not tracked systematically
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Continuous improvement initiatives lacked reliable data
Disconnected Financial System
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Production and inventory data did not flow directly into Tally
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Manual reconciliation increased workload and risk of mismatches
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Finance and operations worked in silos
The ManufApp Solution
To address these challenges, ManufApp delivered a comprehensive, modular solution tailored for the machining-heavy context of Pushti Metals:
1. Production Planning & Scheduling
Interactive Plan vs Actual dashboards enabled planners and leadership to:
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Compare daily production targets against real-time output
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Identify machine-level bottlenecks across 50+ CNC/VMC machines
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Dynamically reschedule jobs based on actual machine availability
Outcome: Improved planning accuracy and shift-level execution.
2. Mobile App for Frontline Operators
Operators were equipped with a mobile app to capture:
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Hourly production quantities
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Rejections and scrap in real time
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Downtime events with reason codes
Outcome: Paper logs were eliminated, improving data accuracy and visibility.
3. OEE Dashboards Across the Machine Fleet
ManufApp enabled real-time OEE tracking, broken down into:
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Availability (uptime vs downtime)
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Performance (speed losses and under-utilisation)
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Quality (rejects and scrap)
Trend analysis across shifts and days supported continuous improvement initiatives.
Seamless Tally Integration
A key highlight was the non-intrusive integration with Tally.
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Existing accounting workflows remained unchanged
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Production, inventory, and rejection data synced automatically
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Costing accuracy and inventory valuation improved
The integration was rolled out in phases, validated through reconciliation reports, and completed with zero production downtime.
The following functional flow illustrates how production, inventory, and costing data moves seamlessly between ManufApp and Tally without altering existing accounting processes.
Additional Functional Capabilities
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Hourly machine-level production tracking
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Real-time rejection and scrap logging
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Downtime categorisation for root-cause analysis
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Operator-level accountability and performance visibility
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Alerts for performance drops or high rejection levels
Impact & Benefits
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Real-time visibility across 50+ CNC/VMC machines
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Early identification of schedule slippages
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Improved machine utilisation and throughput
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Reduced manual errors and scrap
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Faster supervisory response on the shop floor
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Lower reconciliation effort and better costing accuracy in Tally
Conclusion
This case demonstrates how ManufApp supports CNC/VMC-heavy machining environments by digitising planning, execution, quality, and financial integration.
By connecting the shop floor with real-time dashboards, mobile data capture, OEE visibility, and seamless Tally integration, the organization moved toward a more data-driven, efficient, and responsive operating model.
ManufApp enabled better decisions across shifts, tighter operational control, and a strong foundation for continuous improvement in precision machining.
