Process Automation Reduces Manual Work by 60% and Boosts Reporting Speed 3X
We built a custom automation platform that streamlined production reporting, eliminated manual handoffs, and gave plant managers real-time visibility into operations.
Who we worked with, what they were trying to fix, and what we shipped on the engagement.
Industry
Industrial Manufacturing
Where
Pune, India
Team size
500+ Employees
Timeline
8 Months
The Background
Manufacturing · Process Automation & ERP
The client ran 4 separate plants on legacy ERPs with paper-based daily reports. Production leads spent most of their day compiling numbers in Excel instead of solving problems on the floor.
We were engaged to design a unified process automation platform that connected plant data, automated reporting, and surfaced actionable insights to leadership in real time.
Engagement scope
DiscoveryUI/UXWeb + mobileIntegrationsQA + launch
Before → After
Every obstacle became a system we shipped.
Read the situation and the fix side by side — one row per problem we solved on this 8 months engagement.
BEFORE#01
Manual daily reporting across 4 plants with inconsistent formats
AFTER#01
Built a central process automation hub integrating all 4 plants
BEFORE#02
No real-time visibility into production bottlenecks
AFTER#02
Automated end-of-shift reporting with anomaly flagging
BEFORE#03
Disconnected legacy ERPs and shop-floor systems
AFTER#03
Connected legacy ERPs via a unified API layer
BEFORE#04
High error rate in inventory and shipment reconciliation
AFTER#04
Replaced paper-based inventory checks with barcode + mobile flows
BEFORE#05
Slow decision-making due to lack of consolidated dashboards
AFTER#05
Delivered real-time executive dashboards with drill-down analytics
●5 blockers→●5 shipped
The Results
Numbers From Production.
Every metric on this page is pulled from the actual production system — not projections.
60%
Reduction in Manual Work
3X
Faster Reporting
from days to hours
90%
Improvement in Data Accuracy
₹2.4Cr
Annual Cost Savings
4
Plants Unified on One Platform
Illustrative outcomes — anonymised composite figures representative of engagements like this one.
Client Testimonial
Our plant managers finally trust the data. What used to take a full day of reconciliation now happens automatically, and we catch issues the same shift they happen.
5.0 from the client team
VO
VP of Operations
Industrial Manufacturer•Client review
Engagement At a Glance
8+
Team size
Senior engineers
8–12
Sprints delivered
2-week cycles
12+
Modularity
Reusable components
3
UAT cycles
Signed off
REPEAT-CLIENT POTENTIAL
Already in active retainer after handoff.
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This case study is an anonymised composite. Client name, sector and outcome metrics have been generalised to illustrate the kind of engagement Mejona delivers — they are not a contractual claim.
