Manufacturing · 4-plant industrial group
Closed-loop operations across plants, products and P&L.
A four-plant industrial group operating on tribal knowledge, conflicting spreadsheets, and lagging monthly reviews. KYRO EDGE rebuilt the operating model end-to-end.
−42%
Cycle time
98.6%
OTIF
−30 hrs/wk
Manual reporting
+27%
Forecast accuracy
Challenge
What was breaking.
- Production, quality and supply data lived in four disconnected stacks across plants.
- Leadership reviewed performance on a lagging monthly cadence with no consensus on the numbers.
- Planning and dispatch resolved differences inside spreadsheets — every week.
- No early-warning signal for quality, downtime or supplier risk.
Approach
How we re-engineered the operating model.
01
Operating model redesign
Re-architected the planning, production and review cadence around real-time signal rather than monthly retrospect.
02
Unified data fabric
Built a single data layer across MES, ERP and quality systems with one shared definition of every KPI.
03
Executive operating console
Designed a CEO-grade dashboard surfacing throughput, OTIF, quality and supplier health in real time.
04
Workflow automation
Automated the highest-friction hand-offs: planning to dispatch, quality to root-cause, supplier to procurement.
"KYRO EDGE didn't sell us software — they redesigned how we operate. The clarity we have now is what we'd been trying to buy for years."
— Managing Director, Industrial Group
Next Step