End-to-End Foundry Workflow Automation for Higher Accuracy & Efficiency

We built CastFlow360, a fully digitised production, QC, subcontracting, costing, and dispatch management system that connects every foundry department with real-time insights. Designed with a Tally-like interface for ease of use, the platform centralises operations across Core, Moulding, Furnace, Fettling, Machining, Stores, QC, and Dispatch.

industry

Manufacturing

Services

System Architecture, Backend Development, Odoo Customization, UI Engineering, Production Digitization

Introduction

Foundries operate with highly interlinked departments, core making, moulding, melting, fettling, machining, subcontracting, QC, and dispatch. Each stage impacts material cost, labour billing, rejection rates, and delivery timelines.

The client needed a unified digital system that could:

Track shift-wise and heat-wise production
Manage QC at every stage with rejection reasons
Handle subcontractor issue-return workflows
Compare planned vs. actual production
Track material consumption and store issues
Automate labour and subcontractor billing
Manage customer orders, dispatch, and pending deliveries
Provide a Tally-like view to simplify data entry

The Challenge

Foundry workflows are deeply interconnected, and digitizing them required solving multiple operational and technical challenges:

Highly interdependent processes across Core, Moulding, Furnace, Fettling, and Machining made the system logic complex.
Heat-wise material consumption and loss calculations needed precise formulas to avoid production discrepancies.
Subcontractor workflows involved partial returns, staged QC checks, and labour billing — difficult to track manually.
Master lists for castings, grades, and patterns were large and inconsistent, requiring cleanup and governance.
Planned vs. actual production comparisons demanded dynamic and real-time calculations.
A Tally-like screen had to be engineered inside Odoo for fast, grid-based data entry — something Odoo does not offer by default.

Our Approach

We engineered a deeply integrated, department-wise production management system tailored to the foundry’s exact workflow.

Department-Wise Production Digitization

Shift-wise logs, heat-wise entries, material usage, and rejection reasons captured in real time.

Subcontractor Workflow Automation

Issue-return management, QC checks, and labour billing streamlined for external machining and related processes.

QC Engine with Rejection Mapping

Mapped raw material, in-process, subcontracted, and customer-end rejections with defect codes and responsible stages.

Planning vs. Actual (PPC) Engine

Production planners can compare planned schedules with actual outputs by shift, heat, and process stage.

Custom Tally-Like Grid Interface

A QWeb + JavaScript-based screen inside Odoo for fast tabular entry and keyboard navigation.

Digitize complex manufacturing operations with confidence.

From foundry workflows to production planning and QC automation, 7Span helps enterprises build custom systems that scale with precision and reliability.