Manufacturing Team Cuts Reporting Time by 87% in 28 Days
The Full Story
Midwest Manufacturing had tried to automate reporting before: Excel macros that broke constantly, an IT project that went nowhere after 6 months. When they came to us, they were skeptical but desperate. Their operations managers were spending half their week just compiling numbers instead of actually managing operations.
In 28 days, we built a system that connects to their ERP, production monitoring, and quality systems. Reports that took 4 hours to compile now generate automatically in 5 minutes. The real win? Leadership finally has real-time visibility into plant performance, and the operations team can focus on actually improving processes instead of documenting them.
The Challenge
Operations managers spent 22+ hours per week compiling production reports from multiple systems. Manual data entry led to errors, and leadership never had real-time visibility into plant performance.
Our Solution
Deployed an AI-powered reporting system that automatically pulls data from production systems, generates daily reports, and delivers executive dashboards, all without manual intervention.
Automated Reporting System
From manual spreadsheets to real-time executive dashboards
Core production and inventory data
- -Production orders and schedules
- -Inventory levels
- -Cost tracking
Real-time machine and production data
- -Machine utilization rates
- -Cycle times
- -Downtime tracking
Pulls from all systems on schedule
- -Hourly data sync
- -Error handling and retry logic
- -Data validation checks
Generates insights and anomaly detection
- -Trend identification
- -Exception flagging
- -Narrative report generation
Daily, weekly, and monthly reports
- -Customizable templates
- -PDF and Excel formats
- -Scheduled distribution
Real-time KPIs and performance metrics
- -Plant performance overview
- -Cost and efficiency trends
- -Mobile-friendly access
Granular production data and alerts
- -Machine-level metrics
- -Quality tracking
- -Exception notifications
The Result
87% Time Reduction
“I was skeptical after our Excel macro disaster. But this actually works. I get 3 hours back every day, and the reports are more accurate than when we did them by hand.”