A major U.S. global manufacturer was plagued by an outdated, paper-based production order workflow that slowed operations, increased errors, and created costly delays across the shop floor. Connective Consulting partnered with their operations, engineering, and production teams to design and implement a modern, digital solution that replaced handwritten orders with an efficient, user-friendly system. Within eight weeks, Connective delivered a working prototype—ultimately scaling to every production line and transforming how work flowed through the facility.

Client Background

This large manufacturing organization operates multiple production lines with high daily order volume. Their processes require precise coordination between planning, scheduling, equipment operators, and quality assurance teams.

The Challenge

The existing paper-driven workflow created several operational challenges:

• Handwritten orders were error-prone, leading to rework and quality issues.

• Physical documents slowed down routing, often causing bottlenecks between stations.

• Manual data entry consumed hours of staff time each day.

• Stacks of paper accumulated across the facility, making information difficult to track or audit.

• Turnaround times were unpredictable, especially during high-volume production windows.

The client recognized the need for modernization but lacked the internal engineering bandwidth and product strategy expertise to drive change quickly.

Connective’s Approach

Connective deployed a cross-functional team of product strategists, UX designers, and full-stack engineers to rapidly diagnose the problem and deliver a scalable solution.

• Conducted interviews across production, operations, and engineering

• Mapped current-state workflows and identified root causes of delays

• Collaborated with frontline operators to understand real-world constraints

• Defined a future-state digital workflow that would reduce friction and eliminate paper

Using agile development and iterative design, Connective built a functional prototype that:

• Digitized production order creation

• Automated data inputs that were previously handwritten

• Streamlined routing between stations

• Provided real-time visibility into order status

• Reduced redundant steps operators previously performed manually

User feedback was integrated continually through:

• Weekly demos

• On-floor usability testing

• Hands-on sessions with operators and supervisors

This ensured the solution matched real workflows—not an idealized process built in isolation.

The Solution

The final digital production order platform included:

• Intuitive UI tailored for frontline operators

• Automated data validation to eliminate common mistakes

• Real-time routing and status updates across stations

• Role-based access for supervisors, planners, and operators

• Scalable architecture that could expand as processes evolved

What was once a handwritten, hand-delivered process became a fast, accurate, and fully digital workflow.

The Impact

The transformation was immediate and measurable:

Scrap and rework dropped 22% in the first quarter, while average order lead time improved by three days. Automated validation removed variability caused by handwriting and manual transcription.

Digital routing eliminated delays caused by transporting paper materials across the facility.

Fewer errors, fewer delays, and reduced manual data entry saved time and reduced waste.

The solution became a new operational standard across the plant.