Streamlined project-based production, inventory, and dispatch workflows for efficient furniture manufacturing operations.

Streamlining Custom Furniture Production and Inventory for a Multi-Unit Furniture Manufacturer Using the Zventory (AI Powered) Industry: Furniture Manufacturing (Modular, Custom, Commercial) Company Size: Mid-scale with 2 factories & 4 retail outlets Modules Used: Inventory, Production, Sales, Purchase, Dispatch, HR, Document Management Key Challenges: Production planning, raw material control, customization workflow, dispatch delays, multi-branch coordination

Background

A well-established furniture manufacturing brand specializing in modular kitchen sets, office furniture, home décor items, and custom-made interior furniture began facing major operational hurdles as demand increased. Despite having a strong customer base and an expanding showroom network, internal management processes lagged behind, especially when it came to production accuracy and meeting delivery deadlines. Their operations involved multiple moving parts:

• Customized orders
• Different material types (wood, boards, laminates, hardware, upholstery)
• Skilled labor dependency
• Multi-layer finishing process
• Multi-branch stock movement
• Time-sensitive installation schedules

The company needed a solution that could simplify the entire workflow — from enquiries to finished furniture dispatch — and provide real-time visibility across branches and factories. They implemented the Zventory (AI Powered), transforming their complete manufacturing cycle.

The Challenges

1. Unorganized Production Workflow

Every furniture order was custom — different sizes, materials, finishes, and fittings. They relied on manual job cards and spreadsheets for:

• Cutting lists
• Material allocation
• Tracking work in progress
• Monitoring deadlines

This caused confusion between cutting, assembly, polishing, and installation teams.

2. Material Wastage & Mismatch

Furniture manufacturing depends heavily on:

• Plywood
• Laminates
• MDF
• Edge bands
• Hardware components

Because stock was loosely managed:

• Material wastage increased
• Blocks of materials were lost or misallocated
• Wrong materials were issued to production
• Purchase teams could not plan accurately

3. Poor Deadline Management

Production timelines kept shifting because:

• Work-in-progress was not clearly visible
• Showrooms lacked real-time production status
• Production managers had no consolidated pending job view

This negatively affected customer commitments and brand reputation.

4. Multi-Branch Coordination Problems

With 4 showrooms and 2 factories:

• Showrooms didn’t know real stock availability
• Factories didn’t receive material requirements early
• Stock transfers were not recorded properly
• High-value hardware items went missing

The Solution Implemented

The furniture company adopted the Zventory (AI Powered), fully integrating all operations into a single online system. ✔ Centralized Sales & Order Management All enquiries, estimates, and customer orders across branches were recorded digitally. Each order was linked to:

• Required materials
• Estimated delivery date
• Production stages
• Dispatch schedule

This ensured clarity for sales, production, and dispatch teams. ✔ BOM for Custom Furniture The ERP enabled creation of:

• Bill of Materials (BOM)
• Material consumption sheets
• Cutting lists
• Component requirement lists

Even highly customized furniture had unique BOMs, ensuring precise material allocation. ✔ Complete Production Workflow Digitization Each production job now moved through:

• Start Production
• Running Production
• Pending Production
• Finished Production

Real-time dashboards tracked:

• Assembly
• Polishing
• Upholstery
• Hardware fitting
• Packaging

Manual job cards were fully eliminated. ✔ Stock & Raw Material Control

• Batch-wise and general stock tracking
• Real-time stock transfers
• Multi-warehouse inventory view
• Automated low-stock alerts

Production teams could see actual material availability, preventing confusion and stoppages. ✔ Automated Purchase Indents Based on BOM and production requirements, the system:

• Auto-generated purchase indents
• Ensured timely procurement
• Reduced emergency buying
• Improved vendor planning

✔ Dispatch & Installation Management The system tracked:

• Completed orders
• Ready-for-dispatch items
• Vehicle logistics
• Delivery status

Installers received job details and documents via WhatsApp and email.

The Results

1. 35% Faster Production Cycles

Clear workflows and job visibility drastically reduced delays.

2. 40% Reduction in Raw Material Wastage

• Accurate material issuance
• Controlled wastage calculation
• Higher cost savings

3. Total Transparency Across Showrooms & Factories

Every showroom gained access to:

• Stock availability
• Production status
• Expected delivery dates

Customer trust improved significantly.

4. 90% On-time Delivery Rate Achieved

Delivery timelines became predictable and reliable.

5. Smooth Multi-Branch Inventory Movement

Stock transfers were fully trackable, eliminating losses and confusion.

6. Better Productivity of Skilled Teams

Carpenters, painters, polishers, upholsterers, and assemblers worked more efficiently due to clearly assigned tasks.

Conclusion

The Zventory (AI Powered) gave the furniture manufacturer complete control over custom and modular production workflows. By connecting sales, production, purchase, and dispatch teams under one system, they achieved smoother operations, reduced wastage, improved profitability, and superior customer experience. This digital transformation enabled the company to handle higher order volumes while maintaining premium quality and faster delivery timelines.