A leading aftermarket automotive parts manufacturer in Indonesia was seeking to modernize its factory operations by eliminating manual reporting and improving coordination between production and warehouse teams.

1. The Challenge

Their traditional methods relied on paper-based logs and manual handoffs, which led to:

• Delayed and inaccurate production data, making it hard to monitor output and identify bottlenecks in real time.

• Poor synchronization between WIP completion and warehouse intake, often resulting in material backlogs and fulfillment delays.

• Limited visibility into operator performance and shift efficiency, hindering continuous improvement efforts.

To meet the demands of higher production volumes and shorter delivery cycles, the company needed a real-time, integrated solution that would streamline reporting, increase transparency, and connect the shop floor directly to back-office systems.

2. Our Solution

We implemented Largo WIP, a digital Work-In-Progress tracking application built to monitor production effectiveness across each step of the manufacturing process. The system was customized to reflect the client’s actual workflows and integrated tightly with their existing ERP platform to ensure seamless data flow from production to inventory.

Key solution components:

• Digital tracking at every production stage using touch-based terminals and mobile devices to capture quantities, defects, and completion times directly from the floor.

• Live dashboards for supervisors and planners, providing actionable insights on line performance, output trends, and WIP status.

• Real-time ERP integration, allowing production data to automatically update inventory levels, material movements, and order progress—eliminating the need for duplicate entries or manual reconciliation.

• Automated warehouse handover, where completed WIP is instantly registered in the system and ready for intake by warehouse staff.

This integration between Largo WIP and the ERP system created a closed-loop data environment, aligning the production, inventory, and fulfillment functions under one digital infrastructure.

3. The Outcome

The rollout of Largo WIP delivered measurable improvements across both production and warehouse operations:

• Real-time production visibility, enabling immediate response to delays, quality issues, or output shortfalls.

• Accurate, real-time updates to the ERP, reducing administrative workload and improving cross-functional decision-making.

• Faster warehouse processing, with instant notification of completed goods ready for intake, reducing idle time and accelerating fulfillment.

• Operator-level performance tracking, supporting a culture of accountability and continuous improvement.

• Improved production planning and material coordination, resulting in smoother operations and higher on-time delivery rates.

With Largo WIP, the client transformed its production management from reactive to proactive—paving the way for data-driven manufacturing at scale. The immediate impact is the production report that might take days to weeks to consolidate now can be accessed with a click of a button.

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Is your organization facing a similar challenge—where fast, accurate, and scalable supply chain digitization is critical?

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