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Furniture Manufacturer

IcSoft MES Implementation at a Leading Indian Furniture Manufacturer

Company Overview

A leading Indian furniture manufacturer, the company holds a dominant position in the market with a 15% market share. It is recognized as India’s largest furniture brand, serving both home and institutional segments. With a strong retail presence of 430+ stores across 84 locations, the company offers a wide range of furniture products.

Headquartered in Mumbai, the company operates in the consumer durables sector and specializes in sheet metal-based furniture manufacturing. It has seven manufacturing facilities located in Mumbai, Haridwar, Shirwal, and Bhagwanpur, and expanded with a new plant in Western India in 2019. Its manufacturing capabilities include punching, bending, welding, powder coating, assembly, and packing, supported by a forward-looking management team focused on innovation and operational excellence.

Business Challenges

  • Frequent supply-side disruptions, especially post-COVID
  • No real-time scheduling software, leading to visibility loss
  • Daily changes in production schedules due to supplier delays

Uncoordinated operations caused:

  • Excess work-in-progress inventory
  • Shortages of required parts
  • Production stoppages and delays

Manual scheduling led to:

  • Quality issues in bending due to unloading/reloading
  • Rework in powder coating
  • Overtime due to peak production loads
  • Paint shop inefficiencies due to manual sequencing and color changeovers
  • Documentation errors from physical drawings
  • Lack of traceability for root cause analysis in quality issues

Objectives

  • Implement a smart manufacturing system in the new Western India plant
  • Achieve real-time visibility across operations
  • Reduce production cycle time and rework
  • Improve delivery reliability and customer confidence
  • Digitize process and product documentation
  • Integrate IIOT, ASRS, and AGVs for smart material handling
  • Support sustainability goals through waste reduction
  • Ensure traceability for quality control and international compliance

Outcomes and Benefits

The company is already experiencing notable benefits from the IcSoft MES implementation. Few salient ones are mentioned below:

  • 50% reduction in production cycle time
  • 1.5% reduction in powder coating rework
  • Overtime cost has been reduced through optimal production leveling
  • Complete visibility into machine loading has led to confident order promising to prospects and win more business.
  • End-to-end traceability, from packet identification to coil and batch number of powders used has also led to more business from international customers.
  • Lesser changeovers have led to reduced waste generation supporting the company’s sustainability initiatives.

Icsoft Solution Implementation

  • Selected IcSoft Manufacturing Execution System (MES) after rigorous evaluation
  • 100+ users onboarded
  • Low-code architecture enabled rapid deployment despite COVID travel restrictions

Modules implemented:

  • Scheduling
  • Quality Management
  • Document Control
  • Process Monitoring
  • Data Acquisition
  • Warehouse Management

Key Features:

  • Finite capacity scheduling with real-time updates
  • Mid-point scheduling for dynamic rescheduling
  • Attribute-based order grouping for efficient paint shop operations
  • Digital documentation for paperless workflows
  • Process-level quality alerts and statistical process control
  • Work order-based machine control
  • End-to-end traceability (coil number, paint batch)
  • Automated material handling via ASRS and AGVs