Overview​

Thanehall collaborated with a well-established client to transition from a fragmented and manual system to a comprehensive and integrated Shop Floor Control System. This solution linked Bill of Materials (BoM), Material Requirements Planning (MRP), Enterprise Resource Planning (ERP), and production testing processes, enabling seamless in-house manufacturing and process oversight.

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Development Highlights

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Challenges Addressed

• The client’s existing system relied on BoMs generated in two separate CAD systems and imported into Excel. Component data was also maintained in Excel, which was sufficient for outsourcing manufacturing to Contract Manufacturing Organisations (CMOs).

• When manufacturing was brought in-house, the lack of an integrated system led to inefficiencies, necessitating the development of a tailored solution.

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Database Integration

• Thanehall designed a centralised database to consolidate and manage components, sub-assemblies, and high-level assemblies.

• Import filters were created for seamless integration of CAD generated BoMs, streamlining data migration and future updates.

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Shop Floor Control System Features

• Implemented process checkpoints to monitor and manage key production stages:

  • Kitting: Ensuring accurate component selection and preparation.​

  • Assembly: Managing sub-assemblies and high-level builds.

  • Test: Automating quality assurance processes.

  • Packing and Dispatch: Ensuring traceability and timely delivery.

• Direct integration with a bespoke MRP and ERP system enabled real-time synchronisation across planning and operational processes.​

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Cloud-Based Transition

• ​The system was deployed as a series of React™ applications connected to a Microsoft SQL Server hosted on Amazon Relational Database Service (Amazon RDS).

• A monitoring and reporting application allowed production line overview from any location.

• Automated reporting functionality delivered real-time progress updates and reports to stakeholders via email.

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Customer Benefits

• Streamlined Operations: The integrated system eliminated manual workflows, improving efficiency and accuracy in production processes.

• Enhanced Monitoring: Cloud-based applications enabled real-time visibility into manufacturing status, empowering better decision-making.

• Cost-Effective Solution: The system’s scalability and modularity made it an ideal choice for startups and small companies similar to our client, offering configuration control, reliability, and traceability within budget constraints.

• Stakeholder Engagement: Automated reporting ensured that key stakeholders remained informed about production progress, enhancing transparency and collaboration.

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Conclusion

This project showcased Thanehall’s ability to design and implement end-to-end manufacturing solutions tailored to client needs. By integrating BoM management, production control, and enterprise resource planning, the Shop Floor Control System delivered measurable improvements in efficiency, traceability, and operational oversight, making it a powerful tool for scaling in-house manufacturing.

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