Introduction and Industry Context
The foundry and casting industry is a backbone of manufacturing, supplying critical components to automotive, machinery, aerospace, and other sectors. This industry faces challenges in ensuring quality control, managing raw materials like metals and alloys, regulating energy usage, and meeting stringent compliance demands. Managing casting recipes, furnace operations, production planning, and traceability across the supply chain requires an integrated solution capable of real-time data management and process automation.
Traditional foundry practices relying on manual entry, spreadsheets, and standalone systems often result in bottlenecks, inaccurate inventory, delayed deliveries, and compliance risks. Digital transformation with SAP Business One delivers a unified ERP platform engineered to optimize all aspects of foundry operations—driving accuracy, efficiency, and sustainable growth.
Key Challenges
- Real-Time Raw Material & Inventory Visibility Gaps
- Complex Production Planning & Furnace Scheduling
- Difficulty in Accurate Costing & Margin Analysis
- Compliance, Chemical Accuracy & Batch Traceability Requirements
Our Solutions
- Integrated Metal, Alloy & Consumable Inventory Control
- Advanced Production & Furnace Scheduling Oversight
- Dynamic Costing With Automated Profitability Insights
- End-to-End Compliance, Quality & Batch Traceability
Implementation Approach
- Discovery: Collaboration with production, quality, procurement, and finance to map unique workflows and challenges.
- Configuration: Custom SAP Business One modules for inventory, production planning, costing, and compliance, tailored to foundry processes.
- Integration: Connections to weighing systems, furnace PLCs, quality labs, and finance platforms.
- Training & Hypercare: User training across departments, floor-level support, and post-live hypercare to drive adoption.
Results & Business Impact (90 days)
| Metric | Improvement | Baseline | Post-Implementation |
|---|---|---|---|
| Inventory Accuracy | 50% increase | 60% | 90% |
| Production Cycle Time | 30% reduction | 10 days | 7 days |
| Cost Overruns | 40% reduction | 20% | 12% |
| Compliance Issue Frequency | 90% reduction | 10/month | 1/month |
Why Clockwork Business Solutions?
Clockwork’s ERP expertise, paired with an in-depth understanding of foundry processes, enables smooth, effective digital transformation.
- SAP Business One configurations customized for casting and foundry workflows.
- Seamless integration with plant machinery, quality control, and finance systems.
- Full lifecycle support, from discovery through deployment and ongoing process improvement.
Conclusion
SAP Business One empowers foundry and casting businesses to digitally orchestrate production, inventory, quality, and compliance—unlocking greater efficiency, lower costs, and stronger customer satisfaction. With a unified ERP backbone, foundries can focus on scaling operations, meeting evolving quality standards, and capturing new opportunities in a competitive global market.