Digitalizing Manufacturing

To modernize operations for a leading American hardware manufacturer, we developed an integrated digital ecosystem that transformed their fragmented, paper-based processes into streamlined, automated workflows.

Overview
Services
How We Did It
Impact

SERVICES

Overview

Our client is one of America’s largest manufacturers and distributors of commercial hardware products, operating 40+ facilities nationwide. Amid rapid growth through multiple acquisitions, their processes were fragmented, ad-hoc, and bogged down by manual, paper-based systems.

This disjointed environment hampered operational efficiency and stifled digital innovation.

With a clear vision to evolve into a digital-first enterprise, the client partnered with us to integrate disparate systems, automate legacy processes, and unlock new digital revenue streams—all while elevating customer experiences and streamlining operations across manufacturing, supply chain, and procurement.

Services

We engineered a comprehensive digital transformation that seamlessly connected isolated ERPs and outdated workflows. Our API-first integration engine broke down silos, enabling real-time data exchange across all operational units.

Utilizing agile DevOps practices and a scalable cloud architecture, we digitized key processes—from production to delivery—accelerating time-to-market and boosting operational transparency.

This robust solution not only reduced manual intervention but also paved the way for continuous innovation, delivering measurable ROI and a competitive edge in the manufacturing landscape.

Opening the ‘Digital’ Doors

We ignited the transformation with an intensive two-week design sprint, engaging the CIO and executive team to crystallize their vision. Immersive workshops, rapid prototyping, and iterative feedback sessions helped us pinpoint critical pain points and digital opportunities.

The result was a compelling prototype and a prioritized roadmap that instantly resonated with the leadership. This agile kickoff unlocked the ‘digital’ doors one step at a time, setting a solid foundation for a multi-year, transformative journey toward operational excellence.

Breaking Barriers to Better Business

The client was using an industry-specific ERP system for their core business, a desktop-based solution with intranet-only access - no integration points or documentation. In addition, most of the newly acquired companies were using their own isolated ERP systems with similar limitations. To build any digital solution, we had to make these systems talk to each other. This was the first and by far the biggest technical challenge.

We analyzed the client’s enterprise systems, architectures, and technical implementations to engineer a platform that orchestrated and integrated their disjointed business and data systems. This removed the roadblocks to reshape the client’s business.

Integration & Automation Platform

As the client’s business was expanding and growing rapidly, we had to make sure that new platforms and apps can evolve, adapt, and scale to meet the changing needs. Our team designed and engineered the platform that orchestrated and integrated multiple systems and offered a reusable API framework to develop automation.

The API-driven platform allowed us to be extremely lean and agile in delivering apps and automation in a matter of days - reducing time to market and costs. The platform is becoming the strategic digital asset that keeps growing as we continue to digitize our client’s key business processes.

Automating the Last-Mile Delivery

The client does the last-mile delivery of finished goods to their customers from their warehouses. The current process was complex and paper-based, involving multiple steps, people, and locations. It often resulted in increased delivery times, missed deliveries, higher costs, and bad customer experiences.

We designed and developed an end-to-end last-mile delivery platform that digitized the entire process for delivery managers, warehouse staff, and fleet drivers in just 60 days. The product enabled key business features like order processing, grouping, shipment design, real-time tracking, real-time monitoring and planning app for delivery managers.

Digitizing Procurement Approvals

The client was using the existing intranet-based system to get approvals for procuring materials and supplies. Purchase requests often got stuck in the approval process and caused significant delays in procuring required raw materials to deliver the client projects. The client wanted us to digitize the entire process and provide transparency, efficiency, and accountability for all purchase approvals.

Digitize Proposal & Discount Approvals

Similar to procurement processes, the client’s sales team was caught up in delays when they needed to get discount approvals for the big sales opportunities. Rapidops was able to digitize the entire process with the workflow automation app that we built for procurement approvals in a matter of days.

Impact

Together with the client team, we have built a digital foundation that will help shape the future of their business. With automation, digitization, and integration of operational processes, the client has realized cost savings, operational efficiencies, and improved customer experiences.

With the real ROI on the table, there is a significant cultural shift to build the digital-first agile business, and we continue to help them transform and grow.

30%

Increase in production efficiency

40%

Eduction in machine downtime

50%

Faster decision-making

60%

Improvement in supply chain visibility