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What problems are you trying to solve in your Manufacturing Department?

Flowgear connects ERP, MES, IoT and quality systems so manufacturers plan confidently, reduce downtime and keep production data flowing.
Practical examples
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Practical Examples and Use Cases Where Flowgear Can Help Manufacturing Departments

Production Planning & Scheduling
Auto‑build schedule from demand
Sales forecasts and live inventory drive the scheduler to create balanced just‑in‑time work orders, reducing excess WIP.
Real‑time adjust on downtime
When a machine reports a fault, Flowgear reschedules jobs, reallocates labour and updates delivery dates in ERP and CRM.
Capacity what‑if simulation
Planners change shift patterns or add overtime in a sandbox; Flowgear shows the cost and delivery impact instantly.
Inventory & Supply Chain
Raw‑material reorder automation
ERP min‑max levels trigger POs to suppliers and create ASN expectations in WMS, ensuring materials arrive on time.
Supplier ASN matching
Inbound ASN data compares to actual receipts; variances raise quality holds or debit notes automatically and alert procurement.
Quality Control & Compliance
Inline SPC alerts
Real‑time statistical checks raise alerts and quarantine lots if measurements drift outside control limits, preventing defects.
Electronic batch record archive
Flowgear stores machine and operator data with the lot history, producing audit‑ready batch records without manual collation.
Shop‑Floor Data Integration
Machine telemetry to ERP
Cycle counts, scrap and downtime feed cost reporting, giving accurate standard‑versus‑actual analysis for each work order.
Energy‑consumption dashboards
IoT meters post power usage to BI so plants can benchmark lines and identify efficiency opportunities.
Predictive Maintenance
Vibration anomaly work orders
Sensor spikes open CMMS work orders, reserve critical spares and notify maintenance teams before failure occurs.
Spare‑parts auto‑replenish
Issue of parts to a work order reduces stock; if below reorder point, Flowgear raises a supplier PO automatically.
Share data across the entire organization with a single source of truth
Real‑time data sync across platforms
Flowgear keeps every connected system in agreement, eliminating data silos and preventing version conflicts company‑wide.
Share Data Across The Entire Organization with a Single Source of Truth
  • Integrate with Internal Systems

    Integrate manufacturing systems with ERP, Inventory, and Finance to streamline production planning, cost tracking, and inventory management.

  • Integrate with Customer and Supplier Systems

    Seamlessly connect manufacturing systems with supplier platforms to manage orders, track deliveries, and ensure the availability of raw materials.

Capture Data from Flat Files (Excel, CSV, PDF, etc.) in Real-Time with 100% Accuracy
  • Automate Manual Data Entry

    Capture financial data from flat files and transfer it directly to your financial systems.

  • Real-Time Processing

    Automatically process incoming flat files in real-time, allowing for faster financial reporting and reconciliation.

  • Error Elimination

    Automate the entire data capture process to eliminate human errors, ensuring consistent and accurate data across all systems.

Production Planning and Scheduling
  • Automated Production Scheduling

    Integrate Manufacturing Execution Systems (MES) or Enterprise Resource Planning (ERP) platforms with production scheduling tools to automatically generate production plans based on real-time inventory levels, customer orders, and machine availability.

  • Real-Time Production Monitoring

    Connect production equipment and systems (e.g., IoT sensors, SCADA) with your ERP and MES to monitor production in real-time. This integration enables quick adjustments to production schedules when issues arise, minimizing downtime and maximizing throughput.

  • Capacity Planning

    Automate the process of capacity planning by integrating demand forecasts, customer orders, and production capacity data. Flowgear helps manufacturers adjust production schedules based on available resources and forecasted demand, optimizing output and reducing bottlenecks.

Inventory and Supply Chain Management
  • Real-Time Inventory Updates

    Integrate your ERP or Warehouse Management System (WMS) with production and procurement systems to maintain real-time visibility of raw material stock levels. This helps avoid production delays due to material shortages.

  • Automated Stock Replenishment

    Flowgear can simplify the reordering process by integrating ERP systems with supplier platforms, triggering automatic purchase orders when stock levels fall below a predefined threshold.

  • Supplier Integration

    Connect your procurement system with suppliers to simplify purchase orders, delivery tracking, and invoicing. This integration helps streamline supplier communications, ensuring timely delivery of raw materials and components.

Quality Control and Compliance
  • Automated Quality Checks

    Integrate your MES with quality management systems (QMS) to simplify quality checks during production. Flowgear can trigger real-time alerts for any deviations from quality standards, ensuring that products meet compliance and customer requirements.

  • Data Capture for Compliance Reporting

    Automatically capture and store production data from connected machines and systems for compliance purposes. Integrating MES and QMS with ERP systems enables the generation of audit-ready compliance reports with minimal manual intervention.

  • Traceability and Recall Management

    Integrate production, inventory, and supply chain systems to maintain full traceability of products and raw materials. In the event of a quality issue, Flowgear can simplify the traceability process, identifying affected batches and expediting recalls.

Production Workflow Automation
  • Automated Work Order Creation

    Flowgear can integrate ERP systems with production equipment and MES to automatically create work orders based on customer orders or stock levels. This reduces manual data entry and ensures timely production starts.

  • Workflow Streamlining

    Connect different stages of the production workflow by integrating systems such as ERP, MES, and WMS. This integration ensures that each step of production is coordinated seamlessly, from raw material handling to finished goods packaging and shipping.

Shop Floor Data Integration
  • Machine Data Integration

    Connect IoT-enabled machines and devices to MES and ERP systems to simplify the collection of shop floor data such as machine performance, production output, and equipment status. This enables proactive maintenance, reducing machine downtime.

  • Predictive Maintenance

    Integrate IoT sensors with maintenance management systems to simplify the scheduling of machine maintenance based on real-time data. Predictive maintenance helps prevent unexpected breakdowns and extends the life of equipment.

  • Energy and Resource Management

    Integrate energy management systems with your MES to track energy consumption during production. This data can be used to optimize production schedules, reduce energy costs, and improve sustainability.

Procurement and Supplier Management
  • Automated Procurement Workflows

    Integrate procurement systems with ERP and supply chain management tools to simplify the entire procurement process. Flowgear ensures purchase orders are generated and approved based on production needs and supplier contracts.

  • Supplier Performance Monitoring

    Connect supplier systems with your ERP to automatically monitor supplier performance based on metrics such as delivery times, quality, and costs. This integration helps manufacturers maintain high-quality standards while optimizing and improving supplier relationships.

  • Supplier Collaboration

    Automate communication with suppliers by integrating collaboration platforms with your procurement system. This ensures that suppliers receive real-time updates on production needs, reducing delays and ensuring timely delivery of raw materials.

Logistics and Distribution Automation
  • Automated Shipping and Delivery

    Integrate your WMS and ERP with logistics and shipping platforms to simplify the creation of shipping labels, delivery scheduling, and shipment tracking. This ensures timely and accurate deliveries to customers.

  • Distribution Network Optimization

    Integrate your logistics and distribution systems with sales and inventory management platforms to simplify the distribution process, ensuring optimal routes, reduced shipping costs, and improved delivery times.

  • Warehouse Automation

    Flowgear can connect WMS with simplified storage and retrieval systems (ASRS), improving inventory handling, picking accuracy, and warehouse space utilization. This automation reduces the need for manual processes on the warehouse floor.

Real-Time Reporting and Analytics
  • Production and Performance Dashboards

    Integrate shop floor data with business intelligence tools (e.g., Power BI, Tableau) to create real-time dashboards that monitor production performance, equipment efficiency, and resource utilization. This provides manufacturers with actionable insights to improve operations.

  • Cost and Waste Tracking

    Connect ERP systems with production and inventory data to track material usage, production costs, and waste generation in real-time. Flowgear helps identify inefficiencies and optimize production costs.

  • Forecasting and Demand Planning

    Automate demand planning by integrating sales forecasting data with production and inventory systems. This allows manufacturers to adjust production schedules based on demand forecasts, improving agility and reducing stockouts or overproduction.

Safety and Compliance Automation
  • Health and Safety Monitoring

    Integrate safety management systems with production equipment to automatically monitor compliance with safety regulations. Real-time data from IoT sensors can trigger alerts if safety thresholds are exceeded, helping to ensure a safe working environment.

  • Regulatory Compliance Reporting

    Automatically generate regulatory reports by integrating ERP, MES, and compliance systems. Flowgear ensures that all production data is captured and reported accurately, reducing the risk of non-compliance.

Ready to automate your workflows?

Strengthen financial controls, ensure compliance, and enhance decision-making through timely, data-driven insights into your company’s financial health and operational efficiency.

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