CALIXTO SYSTEMS PRIVATE LIMITED
CALIXTO SYSTEMS PRIVATE LIMITED
CALIXTO SYSTEMS PRIVATE LIMITED
Connecting materials to live orders at CALIXTO SYSTEMS PRIVATE LIMITED

Connecting materials to live orders at CALIXTO SYSTEMS PRIVATE LIMITED

Connecting materials to live orders at CALIXTO SYSTEMS PRIVATE LIMITED

The team moved from ad-hoc tracking to one live view of WIP, shortages, and readiness. (case 759)

36%

Faster month-end reconciliation

36%

Faster month-end reconciliation

₹7 L/yr

Working capital freed from slow-movers

₹7 L/yr

Working capital freed from slow-movers

32%

Reduction in emergency purchases

32%

Reduction in emergency purchases

Hero Background

About CALIXTO SYSTEMS PRIVATE LIMITED

About CALIXTO SYSTEMS PRIVATE LIMITED

CALIXTO SYSTEMS PRIVATE LIMITED operates from Bangalore and builds custom spares for OEM customers. As a small-scale engineering unit running extended shifts during peak weeks, they work with a mix of make-to-stock and make-to-order model and separate RM and FG stores. They needed a centralised workflow to reduce daily follow-ups and keep commitments predictable.

Workspace Icon

Engineering

Industry

Workspace Icon

Engineering

Industry

Workspace Icon

Engineering

Industry

Workspace Icon

Small

Company Size

Workspace Icon

Small

Company Size

Workspace Icon

Small

Company Size

Workspace Icon

Bangalore

Location

Workspace Icon

Bangalore

Location

Workspace Icon

Bangalore

Location

Workspace Icon

WIP tracking across multiple workcentres with stage ownership

Use Cases

Workspace Icon

WIP tracking across multiple workcentres with stage ownership

Use Cases

Workspace Icon

WIP tracking across multiple workcentres with stage ownership

Use Cases

Challenges

Job Planning status was shared via Excel-based plan, so WIP clarity broke during staggered shifts.

Job Planning status was shared via Excel-based plan, so WIP clarity broke during staggered shifts.

Job Planning status was shared via Excel-based plan, so WIP clarity broke during staggered shifts.

Bought-Outs shortages showed up late, causing emergency buys and delays on precision parts.

Bought-Outs shortages showed up late, causing emergency buys and delays on precision parts.

Bought-Outs shortages showed up late, causing emergency buys and delays on precision parts.

Dispatch dates were promised before checks for custom job tracking, causing reshuffles (month-end GST pressure). when multiple orders overlapped.

Dispatch dates were promised before checks for custom job tracking, causing reshuffles (month-end GST pressure). when multiple orders overlapped.

Dispatch dates were promised before checks for custom job tracking, causing reshuffles (month-end GST pressure). when multiple orders overlapped.

Workcentre progress captured at source

Workcentre progress captured at source

Workcentre progress captured at source

Earlier, CALIXTO SYSTEMS PRIVATE LIMITED relied on WhatsApp-based follow-ups and calls to confirm packing progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Earlier, CALIXTO SYSTEMS PRIVATE LIMITED relied on WhatsApp-based follow-ups and calls to confirm packing progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Earlier, CALIXTO SYSTEMS PRIVATE LIMITED relied on WhatsApp-based follow-ups and calls to confirm packing progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Shortage list with vendor dates

Shortage list with vendor dates

Shortage list with vendor dates

Earlier, buying for raw bars was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and tooling components, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across single stores.

Earlier, buying for raw bars was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and tooling components, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across single stores.

Earlier, buying for raw bars was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and tooling components, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across single stores.

Fewer last-minute dispatch changes

Fewer last-minute dispatch changes

Fewer last-minute dispatch changes

Earlier, dispatch dates were committed before checks on promise-date accuracy. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-stock model and OEM customers.

Earlier, dispatch dates were committed before checks on promise-date accuracy. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-stock model and OEM customers.

Earlier, dispatch dates were committed before checks on promise-date accuracy. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-stock model and OEM customers.

More like this

Bromil Auto Technologies Private Limited

Bromil Auto Technologies Private Limited transformed its operational workflow by implementing a centralized system to streamline assembly progress and improve dispatch reliability. The company faced significant challenges, including unclear WIP visibility during staggered shifts and late identification of coolant shortages, which led to emergency purchases. By enhancing ownership at each stage and linking materials to live orders, they achieved greater predictability in their dispatch commitments and improved overall efficiency. This innovative approach not only refined their processes but also aimed to reduce the pressure on inventory management.

Read More

Automed Material Handling Solutions Private Limited

In a dynamic auto ancillary environment, Automed Material Handling Solutions Private Limited faced operational challenges including fragmented communication, last-minute dispatch changes, and delays due to tool shortages. By implementing a centralized workflow, the company transformed its planning process, creating a unified view that enhanced accountability and streamlined vendor management. This approach not only improved efficiency but also set the stage for more predictable operations across their make-to-order model. The case study delves into how these strategic adjustments reshaped their operational landscape.

Read More

CROSS FLOW INDIA

In a bid to streamline operations, CROSS FLOW INDIA adopted a centralized workflow to enhance visibility and accountability across its manufacturing processes. The company faced challenges such as unclear work-in-progress tracking, late identification of shortages, and premature dispatch commitments that led to inefficiencies. By implementing a structured approach to daily planning and requirement-driven purchasing, they aimed to improve predictability and reduce delays. This transformation not only enhanced operational clarity but also aimed to foster a more responsive and efficient production environment.

Read More

Hero Background
Know your Business
without guesswork.
Just Ask!

Made in India | 100% Data Secure | Built by IIT/IIM Graduates

Hero Background
Run your Factory
Without Firefighting.
Start Today!

Made in India | 100% Data Secure | Built by IIT/IIM Graduates

Hero Background
Run your Factory
Without Firefighting.
Start Today!

Made in India | 100% Data Secure | Built by IIT/IIM Graduates