Zventory’s AI-powered system helped a machinery manufacturer streamline complex BOMs, minimize production delays, and improve project profitability.

Optimizing Complex BOMs, Reducing Production Delays & Improving Project Profitability for a Machinery & Equipment Manufacturer Using the Zventory (AI Powered)

Industry: Industrial Machinery, Automation Equipment, Fabrication Machines, Custom Engineering Solutions

Company Size: 220+ employees, 2 manufacturing units, project-based workflow

Modules Used: Inventory, Production, Sales, Purchase, Dispatch, DMS, QC, HR

Key Challenges: Multi-level BOM, long production cycles, procurement delays, design revisions, tracking complex assemblies

Background

A machinery & industrial equipment manufacturer producing automated packaging machines, hydraulic press systems, conveyor solutions, and customized industrial machines faced challenges due to complex production workflows. Every machine required detailed engineering drawings, multi-level BOMs, dozens of fabricated and purchased parts, specialized components, and rigorous testing.

Operations were project-driven with long manufacturing cycles, and existing disconnected systems made it hard to track progress, manage inventory, or ensure on-time project completion. To improve efficiency and scale operations, they implemented the Zventory (AI Powered).

The Challenges

1. Complex Multi-Level BOM Structure

BOM issues caused:

• Missing components during assembly
• Incorrect material planning
• Duplication of parts
• Confusion in engineering change requests

2. Production Delays Due to Supply Shortages

Without integration:

• Purchase unaware of long lead-time items
• Critical components arrived late
• Production halted frequently
• Delivery timelines extended

3. Difficulty Tracking Project Progress

Hundreds of activities per machine were tracked manually:

• Fabrication
• Machining
• Painting
• Electrical installation
• Assembly
• Calibration
• Testing

Manual tracking caused missing updates, inaccurate timelines, and poor inter-department coordination.

4. Revision Management Problems

Frequent design changes without a centralized system led to:

• Old drawings being used
• Increased rework
• Material wastage

5. High Cost of Rework & Delays

• Late project delivery
• Cost overruns
• Customer dissatisfaction
• Lower profit margins

6. Purchase Planning Was Weak

• Lack of visibility on upcoming jobs
• Stock availability for sub-assemblies unknown
• No data on long lead-time items
• Material requirement insights missing

The Solution Implemented

The Zventory (AI Powered) brought complete visibility, automation, and control over machinery manufacturing.

✔ Multi-Level BOM Automation

• Parent assembly, sub-assembly, components, raw materials, purchased parts
• Version control & approval workflows
• Material requirement planning (MRP)
• Auto-calculation of quantities

✔ Production Workflow Digitization

• Start Production → Running → Pending → Finished Production
• Real-time progress visibility
• Delayed activity alerts & workload distribution
• Bottleneck identification

✔ Auto Purchase Indent & Vendor Coordination

• Automated purchase indents based on BOM & stock shortage
• Lead-time analysis and proactive vendor coordination
• Reduced delays in critical components

✔ Document Management System for Drawings & Revisions

• CAD drawings, electrical diagrams, hydraulic schematics
• Customer approvals and engineering change requests (ECR)
• Ensured latest versions used, reducing rework by 40%

✔ Quality Control Integration

• Alignment, load testing, motor performance
• Safety checks & vibration analysis
• Digitally linked to projects

✔ Inventory & Warehouse Optimization

• Stock transfers & batch-wise component tracking
• Real-time availability view
• Controlled material issuance

✔ Dispatch, Installation & Service Coordination

• Auto-generated dispatch documentation
• Logistics assignments & installation instructions
• Improved after-sales service quality

The Results

1. 45% Faster Project Completion
2. 35% Reduction in Rework
3. 50% Faster Purchase Planning
4. Improved Profit Margins
5. Zero Missing Components During Assembly
6. Better Customer Satisfaction

Conclusion

The Zventory (AI Powered) modernized the machinery manufacturer’s operations by providing complete control over BOMs, production, purchase, QC, dispatch, and engineering documentation. The company reduced delays, improved quality, optimized costs, and enhanced customer trust—enabling them to handle more complex projects with confidence and precision.