For a large cement manufacturing factory located in remote village area in India, the challenge was to manage their inventory, production planning, procurement of raw material and delivery of finished goods. With over 1000+ inventory items and warehouse spread over 2 acres it was all haywire to large extent. Company senior management team being miles away in Mumbai HQ was expecting production to go smooth and get real-time reports. The material suppliers on other hand were expecting detailed purchase order and a better payout performance for their invoices.

Existing system in place were having challenges to manage with multiple software applications, multiple entries of same data in different system, non-integrated or non-compatible system caused integration between systems. Different table structures and data elements restricted creating detailed report.

Our experts deployed a team of 2 members to study the existing system and the expected process at the factory. They also captured management expectations and supplier requirements to include in their design.

Sybase SQL server was chosen and using DWB and RWB (Data Work Bench and Report Work Bench) the entire system was built from scratch on Unix platform using Client-Server architecture. The application was installed on the mini-computer installed on the computer/IT department of the factory. System was used in a multi-user environment across factory with distributed network for gate entry, store-entry, production requisition, accounts-payable and management reporting.

Existing data were migrated out from legacy systems, restructured, cleansed and then imported to the new system to provide reporting based on past and current data.

Project was successfully completed to client satisfaction. Overall period for system design and development was about 10 months with a team size of 4-5 people including system architect, DBAs and developers.