Case StudyFabrication
Steel Fabrication: WIP visibility and flow control
A fabrication business achieved better schedule reliability by digitizing WIP tracking across cutting, welding, and finishing.
13 Apr 20261 min readBy AICAN Customer Team
Fabrication | WIP blind spots caused dispatch uncertainty
A fabrication business achieved better schedule reliability by digitizing WIP tracking across cutting, welding, and finishing.
The Reality
- Work order status was updated manually and inconsistently.
- Inter-stage handoff delays were invisible to planners.
- Priority changes did not propagate quickly to lines.
The Cost
- Frequent dispatch slippage and overtime planning.
- Idle time at downstream stages due to poor sequencing.
- Low confidence in committed delivery dates.
The Fix
Digitize
- Tracked every job card across stage transitions.
- Logged start/hold/complete events with reasons.
- Connected WIP boards with dispatch commitments.
Optimize
- Highlighted queue bottlenecks by stage and shift.
- Balanced sequencing based on due date and load.
- Reduced hidden waiting time in handoff-heavy routes.
Scale
- Automated delay alerts for critical jobs.
- Enabled cross-team resolution workflows with owners.
- Expanded same WIP discipline to outsourced processes.
The Result
Before: WIP was opaque and planning accuracy stayed low.
After: Stage-level visibility improved throughput and dispatch confidence.
Digitize what you have. Optimize what you can see. Scale what you have earned.