Case Study: How Nutshell ERP Transformed a Fasteners Manufacturing Company

Overview

A leading fasteners manufacturer, specializing in precision-engineered bolts, screws, and nuts, faced growing challenges in managing production complexity, inventory costs, and customer demands. They partnered with Nutshell Infosoft to implement a tailored ERP solution for fasteners manufacturing, driving digital transformation across their operations.

Business Challenges

❌ Inefficient Production Scheduling

Manual scheduling across multiple machines caused frequent bottlenecks, underutilized equipment, and delays in fulfilling orders.

❌ High Inventory Costs & Stock-Outs

Poor demand forecasting led to excess inventory tying up capital, while still suffering from raw material shortages at critical times.

❌ Inconsistent Quality Management

Paper-based quality checks made it hard to maintain consistent standards, trace defects, and comply with industry certifications.

❌ Limited Real-Time Visibility

Disconnected systems meant decision-makers lacked real-time data on production status, inventory health, and order delivery timelines.

The Nutshell ERP Solution

Nutshell Infosoft implemented a customized ERP software for fasteners manufacturing, integrating all core business functions on a single platform. Key modules included:

✅ Production Planning & Shop Floor Control

• Automated job scheduling and machine allocation reduced idle time and maximized throughput.

• Live dashboards helped supervisors monitor work orders and resolve bottlenecks instantly.

✅ Inventory & Material Management

• Advanced MRP (Material Requirements Planning) optimized stock levels, preventing overstocking and shortages.

• Barcode-enabled tracking ensured full traceability from raw material to finished product.

✅ Quality Management

• In-process and final inspections were streamlined within the ERP, capturing real-time data.

• Non-conformance reports and corrective actions improved quality consistency and compliance.

✅ Sales & CRM Integration

• Sales orders linked directly to production and inventory, improving order accuracy and delivery commitments.

• Customer histories and proactive follow-ups boosted repeat business.

✅ Finance & Costing

• Automated cost tracking provided clear insights into margins by product line and order.

• Integrated accounting simplified invoicing and payments.

✅ Business Analytics & Reporting

• Custom KPIs and real-time dashboards delivered actionable insights into OEE (Overall Equipment Effectiveness), rejection rates, and on-time delivery.

Results Delivered

🚀 Increased Efficiency & Production Output

• Production efficiency improved by 22%, with optimized scheduling reducing machine idle time.

💰 Reduced Inventory Costs

• Inventory carrying costs dropped by 30%, freeing up working capital through accurate demand planning.

🏆 Improved On-Time Delivery

• On-time delivery performance rose from 78% to 96%, strengthening customer trust and retention.

⚙️ Enhanced Quality Control

• Quality rejections decreased by 15%, supported by standardized inspections and digital traceability.

📈 Real-Time Decision-Making

• Leadership gained complete visibility into plant operations, enabling faster, data-driven decisions.