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Case Study Manufacturing ERP ● Live

How we built a Production OS
that increased manufacturing
efficiency by 30%

A full case study on the KRG Medifabb Production Operating System — from problem diagnosis to live deployment in 6 weeks.

30%
Efficiency Gain
25%
Faster Payroll
100%
Data Integrity
6 Wks
To Deployment
Live
On Vercel
Client
KRG Medifabb Pvt Ltd
Industry
Medical Disposables Manufacturing
Location
Chennai, Tamil Nadu
Timeline
Dec 2025 — Jan 2026
Tech Stack
React · FastAPI · SQLite · Vercel
Status
● Live in Production

01. The Problem

KRG Medifabb is a growing medical disposables manufacturer in Chennai producing surgical drapes, gowns, and procedure packs. As the business scaled to 100+ employees and multiple production lines, their operations were completely manual — spreadsheets, paper registers, and WhatsApp messages.

This caused three critical problems that were hurting profitability:

Payroll took 2–3 days every month
Manual attendance tracking, OT calculations, and deduction computation across 100+ workers caused constant delays and errors.
No real-time production visibility
Management had no live view of output per line, material consumption, or waste levels. Decisions were made 24–48 hours late.
Inventory was permanently inaccurate
Raw material stock was tracked in a notebook. Overordering and stockouts were causing significant financial waste every month.

02. Our Approach

We spent 2 weeks on-site studying every workflow before writing a single line of code. We mapped every manual process, understood the factory floor logic, and designed the system around how the workers actually operated — not how we thought they should.

The result was a custom Production OS with four integrated modules, all accessible from any device on the factory floor:

📊
Production Dashboard
Real-time output tracking per production line, shift-wise comparisons, daily/weekly/monthly reports, waste percentage alerts.
👥
HR & Payroll Module
Digital attendance, OT auto-calculation, deduction management. Payroll processing reduced from 3 days to under 3 hours.
📦
Inventory Control
Live raw material tracking, automated reorder alerts, consumption vs. production reconciliation, supplier ledger.
📋
Automated Reports
One-click daily summary, weekly performance reports, and monthly P&L-ready production data — automatically generated.

03. Technology Stack

React 18 FastAPI (Python) SQLite Vercel TailwindCSS Recharts

We chose React + FastAPI for the speed of development and the ability to deploy anywhere. SQLite was deliberately chosen over a cloud database because the factory has intermittent internet — the system needed to work offline and sync when connected.

04. Results After 60 Days

30%
Overall Efficiency
25%
Payroll Time Saved
10%
Waste Reduction
100%
Data Accuracy
"

SWEN TECH transformed our production workflow with their custom Operating System. The real-time tracking and automated calculations have increased our efficiency by 30%. Their technical expertise and dedication to quality are unmatched.

RK
Rajesh Kumar
Operations Director, KRG Medifabb Pvt Ltd

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