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Powder coating, 85 employees

From three spreadsheets to one production plan

A powder coating plant running two oven lines, planned on a whiteboard and three spreadsheets that only one person fully understood.

A powder coating plant running two oven lines, planned on a whiteboard and three spreadsheets that only one person fully understood.
Results

Measured the same way before and after.

Planning effort3 hours a weekfrom 2 days
On-time delivery96%from 81%
Live in13 weeks
Where they started

The situation

Orders arrived by email and were written onto a whiteboard in the planning office. Three spreadsheets sat behind it: one for the oven schedule, one for powder stock and one that reconciled the two.

The planner could not take a holiday. Twice a year the plant ran a batch in the wrong colour because the whiteboard and the spreadsheet disagreed, and nobody could say which had been right.

What we did

The work

We spent the first week of the quick scan on the floor, timing changeovers and watching how work really moved between the two oven lines.

Odoo Manufacturing with a work centre per oven line and capacity that reflects the real changeover time. Quality checks per batch, recorded at the line on a tablet. Inventory for powder stock, with reorder rules on the fifteen colours that move every week.

No customisation beyond two report layouts. The planning board is standard, and it is standard on purpose: it survives the next upgrade.

What changed

The result

Planning went from two days a week in spreadsheets to about three hours in the system, and it is now done by two people rather than one.

On-time delivery moved from 81% to 96% over the first two quarters, measured the same way before and after. The plant went live thirteen weeks after kick-off, on a date it had set itself.

They did not sell us modules. They spent a week on our shop floor first.

Operations director, Velmond Coatings
Apps used

What this project runs on today.

ManufacturingQualityInventoryPurchaseAccounting
Next step

Different plant, same first step.

A quick scan is one week, at a fixed price, and the report is yours either way.

What a quick scan is

  • One week. Two consultants, two days on site, the report a week later.
  • Fixed price. Quoted before we start, and it does not move.
  • The report is yours. Whether you continue with us or not, and whoever you take it to.

Brightmoor is a fictional company created for demonstration purposes. This project did not happen, the client does not exist, and the before and after figures are illustrative.