Highlights
- 50+ CNC & VMC machines digitised
- Real-time production planning & scheduling via Plan vs Production dashboards
- Mobile app for frontline operators to record production counts, rejections, and downtime
- OEE dashboards for visibility into machine availability, performance, and quality
- Seamless Tally integration with zero disruption to existing finance workflows
- Improved visibility, accuracy & decision-making across planning, operations & accounting
About Pushti Metals
Pushti Metals (headquartered in Uttarakhand, India) is a well-established machining company supplying high-precision components to automobile customers. With a shop floor boasting more than 50 CNC (Computer Numerical Control) and VMC (Vertical Machining Center) machines, they operate in a high-volume, precision-critical manufacturing environment.
Their operations demand strict adherence to production schedules, tight quality control, and robust financial tracking. Before their engagement with ManufApp, many of these processes were managed manually, which limited visibility and slowed down decision-making.
Challenges
Before implementing ManufApp, Pushti Metals faced several key operational hurdles:
- Planning & Scheduling Gaps
- Production planning was handled through spreadsheets or manual methods.
- There was no live mechanism to compare planned vs actual output on a daily basis.
- Lack of real-time insights made it hard to reschedule or reallocate jobs dynamically when delays or machine issues arose.
- Production planning was handled through spreadsheets or manual methods.
- Manual Shop-Floor Recording
- Operators recorded production numbers, defects, and downtime on paper or in local logs.
- This introduced delays, data inconsistencies, and human errors.
- Because information was not digitised, supervisors had limited real-time visibility.
- Operators recorded production numbers, defects, and downtime on paper or in local logs.
- Lack of Comprehensive OEE (Overall Equipment Effectiveness) Visibility
- Despite having a large fleet of CNCs and VMCs, management had no consolidated, real-time view of machine utilization.
- Losses in availability (e.g., idle time), performance, and quality were not systematically tracked or analyzed.
- Continuous improvement efforts were constrained by the absence of data-driven insights.
- Despite having a large fleet of CNCs and VMCs, management had no consolidated, real-time view of machine utilization.
- Disconnected Financial System
- Production data and inventory transactions did not flow directly into Tally, their accounting software.
- This led to reconciliation delays, manual overhead, and potential mismatches in costing or inventory valuations.
- Finance and operations teams worked in silos, reducing process efficiency.
- Production data and inventory transactions did not flow directly into Tally, their accounting software.
The ManufApp Solution
To address these challenges, ManufApp delivered a comprehensive, modular solution tailored for the machining-heavy context of Pushti Metals:
- Production Planning & Scheduling Dashboard
Below is a real snapshot of the ManufApp Production Planning & Scheduling dashboard used at Pushti Metals, showing the CNC/VMC machine schedule and plan vs actual visibility.
- Built interactive Plan vs Actual dashboards. These allowed leadership and planners to:
- Visualize daily production targets vs real-time achievement.
- Identify machine-level bottlenecks across the 50+ CNC/VMC machines.
- Re-schedule jobs dynamically based on actual machine availability or unexpected disruptions.
- Visualize daily production targets vs real-time achievement.
- This significantly improved planning accuracy and shift-level execution.
- Mobile App for Frontline Operators
Below is an actual screen from ManufApp’s mobile interface, where operators record hourly production, rejections, and downtime in real time.
- Operators on the shop floor were equipped with a user-friendly mobile app to record:
- Produced quantities (on an hourly basis)
- Rejections and scrap counts (real-time)
- Downtime events (with reasons)
- Produced quantities (on an hourly basis)
- This replaced paper-based logs, dramatically improving data accuracy and real-time visibility.
- OEE Dashboards Across the Machine Fleet
- By digitising machine-level data, ManufApp enabled Pushti Metals to track OEE in real-time, breaking it down into:
- Availability (uptime vs downtime)
- Performance (speed losses, under-utilization)
- Quality (rejects, scrap)
- Availability (uptime vs downtime)
- Trend analysis over days and shifts provided insights for continuous improvement, leading to reduced idle time and more effective utilization.
- By digitising machine-level data, ManufApp enabled Pushti Metals to track OEE in real-time, breaking it down into:
- Seamless Tally Integration
- A major highlight: the integration with Tally was non-intrusive and executed with zero operational downtime.
- Key design points:
- Existing accounting workflows remained unchanged — no retraining required.
- Production, inventory, and rejection data automatically synced into Tally.
- Real-time updates improved costing accuracy and inventory tracking.
- Existing accounting workflows remained unchanged — no retraining required.
- This gave Pushti Metals the benefits of advanced digital shop-floor systems without disrupting their financial backbone.
- A major highlight: the integration with Tally was non-intrusive and executed with zero operational downtime.
Additional Functional Flows & Features
To further strengthen operational rigor, ManufApp also implemented:
- Hourly Production Tracking: Every CNC/VMC machine’s output is tracked on an hourly basis, giving planners and supervisors granular visibility into production throughput and shift-wise performance.
- Real-Time Rejection Tracking: Scrap, rejections, or defectives are recorded in the same shift, enabling immediate feedback loops. This helps the next shift adjust its targets or processes proactively to minimize waste.
- Downtime Categorisation: Downtime events are logged with categories (e.g., maintenance, tooling, setup), enabling root-cause analysis.
- Operator Accountability: Each operator’s inputs (production, downtime, rejections) are tagged, helping with performance assessment and training.
- Alerts & Notifications: If a machine’s performance drops below a predefined threshold, or rejects exceed a limit, the system triggers alerts for supervisory attention.
Tally Integration – Deep Dive
Given that smooth ERP/Accounting integration is often a major pain point, it’s worth outlining how ManufApp handled this aspect:
- Data Flow: Key transactional data from shop-floor (produced units, rejected units, scrap) flows into Tally automatically.
- No Disruption Implementation: The integration was architected such that existing Tally setups, ledgers, accounts, and workflows were untouched.
- Incremental Rollout: Integration was rolled out in phases — first in pilot lines, validated there, and then scaled to all machines — mitigating risk.
- Data Validation & Reconciliation: ManufApp provided reconciliation reports to finance during the rollout to ensure that data matched, building confidence before full cutover.
- Zero Downtime Cutover: Because the integration did not require shutting down production or freezing operations, business continuity was maintained throughout.
The following functional flow illustrates how production, inventory, and costing data moves seamlessly between ManufApp and Tally without altering existing accounting processes.
Impact & Benefits
Though exact numeric metrics (e.g., % increase in OEE, cost savings, reduction in rejections) will need to be filled in based on Pushti Metals’ internal data, the qualitative and process-level benefits are significant:
- Better Decision-Making: Real-time data from 50+ machines gives planners and management unprecedented visibility.
- Improved Schedule Adherence: With Plan vs Actual dashboards, the team now identifies schedule slippages early and reschedules dynamically.
- Higher Utilization & Throughput: OEE insights help reduce idle time, improving machine uptime and throughput.
- Reduced Errors & Waste: Moving away from manual logs decreased human error; real-time rejection tracking helps minimize scrap.
- Operational Efficiency: The mobile app streamlines data entry, saving time and enabling supervisors to focus on continuous improvement rather than reconciliation.
- Finance Effectiveness: Automated Tally integration reduces reconciliation workload, improves costing accuracy, and ensures real-time inventory visibility.
Conclusion
The Pushti Metals–ManufApp engagement is a compelling proof point of ManufApp’s strength in the machining industry, particularly in environments with heavy CNC and VMC usage. Through digitisation of planning, operations, and quality, and by integrating tightly (yet non-disruptively) with Tally, ManufApp helped transform Pushti Metals into a more data-driven, efficient, and responsive operation.
This case clearly illustrates how ManufApp:
- Supports high-volume, precision machining plants
- Provides real-time production and quality visibility
- Enhances decision-making across shifts
- Bridges the gap between shop floor and finance seamlessly