From 70+ manual reports to planning system in 3 months

/ Goals and challenges

Building a production planning system

1. Manual data transfer from 70+ reports

The challenge was to create a centralized platform integrating dozens of current production reports, inventory status reports, production forecasts, and ERP system data into a single source of truth.

2. Accelerate order-to-production process

Accelerate the process from customer order to start of production by eliminating manual data processing between systems and enabling more accurate and reliable response to market demands.

3. Improve production planning quality

Gain visibility into production processes, seasonal patterns, and market trends while enhancing forecasting accuracy to support strategic budget planning and drive business growth.

4. Manage organizational change

Address employee concerns about job displacement due to process automation and demonstrate that the new system enhances their capabilities rather than replacing them.

5. Ensure process stability and continuity

Deliver a system that assumes 100% responsibility for production planning processes without disrupting critical business operations or compromising seamless export operations to 60+ countries.

We had the impression that you understood what we wanted to achieve better than we did ourselves. This was completely missing in our interactions with other vendors. I didn't have to chase for attention - you were the ones asking about progress and proposing solutions.

Konrad Wesołek

Production Planner, ZPM Biernacki

/ Context of cooperation

From 70+ manual reports to unified production planning

The IT Director at ZPM Biernacki was seeking a company to help him build a production planning system in Oracle APEX independently. He had a clear vision: "We wanted technical support, but development was to be led by our own team."

A production planning system for a company exporting to 60+ countries with over 2,000 product SKUs presents significant complexity. It requires expertise not only in low-code system development (like Oracle APEX in this case) but also in process design and data management. This wasn't simply about writing code. It required connecting dispersed data sources into a unified process while ensuring continuity of critical business operations.

The client decided to trust us with the entire project. Out of the companies he spoke with, he chose us based on our approach to problem analysis and our experience with similar implementations in the manufacturing industry.

Today, ZPM Biernacki’s entire production planning is based on the new system and takes 75% less time.

/ Solution

Real-time production planning

The solution replaced a complex manual process where planners had to extract 70+ reports daily from warehouse systems, paste data into spreadsheets, and manually add production forecasts and order information from the ERP system.

Key technical achievements:

• Real-time data integration: Connected Oracle APEX with warehouse systems and ERP to automatically process extensive daily production records across all product categories.
• Unified data model: Transformed the spreadsheet-based categorization system into a flexible, dynamic structure where products can be easily reassigned between groups and categories.
• Performance optimization: Designed queries to efficiently handle massive volumes of production data while providing real-time insights.
• Automated reporting: Eliminated manual data transfer by creating automated workflows that pull current production reports, inventory status, and order data into a single platform.

The system now automatically calculates production balances that previously required manual spreadsheet work, with all information accessible through one centralized interface.

/ Impact

From manual processes to automated efficiency

1. 75% reduction on manual data processing

The planning team saves 75% of the time previously spent on manual data processing and coordination between systems.

2. Operations accelerated

Eliminating manual data processing significantly accelerated the order-to-production process, improving customer service across 60+ export countries.

3. A single source of truth

Integration of dispersed systems into a single source of truth and operations enables better operations management and faster business decision-making across the entire organization.

4. Improved data quality

The system reinforces data validation at order entry, preventing incomplete submissions that previously caused delays and accountability issues between departments.

5. Reduced operational risk

Process automation minimizes the risk of human error and ensures continuity of critical business operations; particularly important for a company serving international markets.

6. Foundation for scaling

The system provides a stable foundation for handling growing order volumes and expansion into new markets without proportionally increasing operational resources.

I really like your approach - I can see that you lead the project and implement it according to best practices. The engagement from your side was visible from the first meeting, and your understanding of our processes was at a high level.

Krystian Kłopocki

Digital Transformation and IT Project Lead, ZPM Biernacki