Zventory’s AI-powered system helped a metal fabrication company optimize material usage, manage complex BOMs, track jobs in real time, improve production planning, control costs, and consistently deliver projects on time across multiple workshops.

Driving Production Efficiency, Material Accuracy & On-Time Delivery Using the Zventory (AI Powered)

Industry: Metal Fabrication & Engineering (Structures, Frames, Custom Fabricated Components)

Company Size: Medium-scale with 2 workshops & multiple job orders daily

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

Key Challenges: Material wastage, inaccurate planning, complex BOMs, delayed production, job tracking, costing issues

Background

A metal fabrication and engineering company specializing in structural frames, industrial brackets, custom metal parts, and heavy machine components struggled to manage project timelines as order volumes increased.

• Mild steel, stainless steel & aluminum raw materials
• Cutting, bending, welding, fabrication, finishing & assembly
• Custom job orders with unique BOMs
• Multiple workshops operating parallelly
• Complex production cycles

Their operations relied on spreadsheets, paper job cards, WhatsApp communication, and basic accounting software. This resulted in frequent delays, material wastage, and unpredictable job costing.

To modernize operations and gain control, the company implemented the Zventory (AI Powered).

The Challenges

1. Material Planning Issues

Metal fabrication requires precise planning of plates, pipes, rods, channels, angles, and fasteners. However:

• Mismatch between available and consumed materials
• No clear tracking of scrap generation
• Incorrect material issued to cutting teams
• Frequent purchase delays due to missing data

2. Production Bottlenecks & Poor Visibility

Each project passed through multiple stages:

• Cutting
• Bending
• Fabrication
• Welding
• Grinding
• Finishing
• Assembly

Manual tracking caused:

• No real-time job status visibility
• Unidentified production bottlenecks
• Poor workload distribution
• Delayed deliveries

3. BOM Complexity & Version Control Issues

Custom fabrication required unique BOMs for every order, leading to:

• Incorrect material sizes in BOMs
• Missing fittings or fasteners
• Unapproved design revisions
• Fabrication teams working on outdated drawings

4. Inconsistent Costing

Without accurate BOM and consumption data:

• Job-wise costing was unreliable
• Profit margins were unclear
• Incorrect quotations were shared with customers
• Excessive scrap went unnoticed

5. Dispatch & Delivery Challenges

Deliveries were delayed due to:

• No clarity on finished vs pending jobs
• Missing QC documentation
• Uncoordinated transport scheduling

6. Weak Purchase Planning

The purchase team lacked visibility into:

• Upcoming job requirements
• Cutting wastage ratios
• Actual stock availability
• Reorder levels

The Solution Implemented

The Zventory (AI Powered) created a fully integrated and transparent operational ecosystem.

✔ Advanced BOM Management

• Multi-level BOM creation
• Revision-controlled BOM updates
• Automatic material requirement calculation
• Clear breakdown of fabrication components

✔ Production Workflow Automation

• Start, running, pending, and finished production tracking
• Real-time job status updates
• Identification of production bottlenecks
• Balanced workload across workshops

✔ Material Issuance & Consumption Tracking

• Correct material issuance to cutting and fabrication
• Scrap and return tracking
• Batch- and size-wise raw material tracking
• Transparent consumption reports

✔ Auto Purchase Indent & Forecasting

• BOM-based purchase indent generation
• Early visibility of material requirements
• Reduced last-minute procurement

✔ Accurate Estimation & Costing

• Job-wise costing
• Material consumption summaries
• Labor hour tracking
• Scrap analysis and profitability insights

✔ Document Management for Drawings & Approvals

• Design drawings
• Revision histories
• Welding procedures
• QC checklists
• Client approvals

✔ Dispatch Management

• Ready vs pending job visibility
• Vehicle-wise loading planning
• Customer delivery tracking

The Results

1. 50% Reduction in Production Delays

2. 35% Drop in Material Wastage

3. 40% Faster Purchase Planning

4. 100% Accuracy in BOM & Design Revision Tracking

5. Transparent & Reliable Job Costing

6. Dispatch Efficiency Improved by 60%

Conclusion

Zventory (AI Powered) delivered complete operational control for the metal fabrication company. By integrating inventory, BOM management, production workflows, purchase planning, costing, documentation, and dispatch, the company achieved higher output, reduced wastage, accurate costing, timely deliveries, and improved customer satisfaction—enabling them to confidently take on larger and more complex projects.