Case studies · Made-to-order manufacturing

Quote to dispatch on one workflow, confirmed from the floor.

Business
Made-to-order furniture, Ludhiana
Size
Two workshops, dealers in nine cities
Ran on
Paper job cards and phone calls
Team
Both founders

A furniture maker with two workshops and dealers in nine cities. Orders moved on paper, and nobody knew where one stood without walking the floor.

What was going wrong

A dealer in Jaipur rings to ask about a dining set his customer ordered. The salesperson does not know. The office does not know. Somebody walks into the workshop, finds the supervisor, and the supervisor looks through a stack of paper job cards to work out whether the piece is in polish or still waiting for fabric. Then somebody rings the dealer back, and by then the answer is a guess.

The same paper moved the whole business. A quote was written by hand and photographed onto WhatsApp. An accepted quote became a job card that a peon carried to the workshop. Material shortages were discovered when a carpenter reached for something that was not there. Two workshops meant two stacks of paper and no way to see them together, so the owner’s only reliable picture of his own business came from walking through it.

None of this was a people problem. Everyone knew their job. The information about the job simply never left the piece of paper it was written on.

What we built

One workflow that carries an order from quote to dispatch. The salesperson raises the quote on a screen, and when the dealer accepts, the same record becomes the job: no retyping, no second number for the same order. Each stage in the workshop is confirmed on a phone by the person who finished it, which takes a few seconds and replaces the paper card entirely. Material needed for a job is listed when the job is raised rather than when a carpenter reaches for it.

The owner has a board. Every live order sits on it in its current stage, both workshops together, ordered by promised date. Anything that has sat in one stage too long stands out without anyone having to look for it. It opens on his phone, which is where he looks at it.

The owner's board with every live order in both workshops in its current stage, ordered by promised date and with the one overdue order standing out, and a supervisor's phone in front of it confirming polish done on one order. A drawing of the screen described here. Not a screenshot.
A drawing of the screen described here. Not a screenshot.

Dealers stopped being a separate job. The dealer update goes out from the same record, so a stage confirmed on the floor is a message the dealer has already received by the time they think to ask. Job cards print from the system for the people who still want paper in front of them, which several did, and that was a reasonable thing to want.

What the owner was left with

Every order visible at every stage, in both workshops, on one board. Job cards and dealer updates are generated rather than typed. The system runs in the company’s own accounts, and the supervisors who confirm stages were trained in their own workshop, one at a time, while we were still there.

The handover review named the two things it did not fix: material purchasing is still a separate conversation with suppliers, and the polish stage still depends on one person’s judgement of when a piece is ready. Both were left alone deliberately, and the note says why, and what we would look at first if the owner wants a second phase.

This was AI and automation work in its plainest form: most of it is a workflow with no model in it at all, because what repeats the same way every time does not need one.

What changed, and by how much.

  1. Cash cycle

    Quote to dispatch

    34 days changed to 25 days

    days from an accepted quote to the piece leaving the workshop, averaged over the month

  2. Errors removed

    Job cards and dealer updates retyped by hand

    120 a week changed to none

    documents typed a second time from a record that already held the same facts

  3. Time returned

    Office time spent chasing order status

    9 hours a week changed to under 1 hour a week

    time at the desk answering where an order has reached, counted against the month before the build

Each measure was agreed in writing before the build, and the starting number taken before it began. 34 days → 25 days is the same measure, counted the same way, after.

AI & automation, in full

All case studies

Start

Write a paragraph. A founder replies within one working day.

A 30-minute call with both founders follows. No deck and no proposal template, just a first read of whether we are the right shape for the problem.

Or by phone or WhatsApp: +91 94330 54299 · WhatsApp (opens in new tab)