About the client

ABi Laser is a UK-based precision engineering company specialising in laser cutting, fabrication and bespoke metalwork. With a reputation for quality and reliability, ABi Laser supports a wide range of industries, delivering projects from prototypes to large production runs.

The challenge

ABi Laser managed job progress and stock control through a combination of their e2i job management system, spreadsheets and paper-based route cards. This created several challenges:

• Job status and workloads were not visible in real-time across the factory.
• Operators recorded completed stages manually, making progress tracking inefficient.
• Stock management lacked automation, leading to inaccuracies in recording deliveries, check-outs and off-cuts.
• Operators had to work with PDFs and OneDrive files, creating duplication and risk of error.
• Additional data such as purchase orders, operator names and part history were not consistently recorded.

ABi Laser needed a system to provide live job visibility, streamline operator workflows and improve stock management.

The solution

Hero developed a bespoke production and stock management platform integrated with e2i, including:

• Factory Display Screens: TV displays across the site showing job status, customer initials, job numbers and workload for 1, 2 or 4 weeks ahead.
• Tablet Operator Interfaces: Stage-specific screens (laser, fold/tap, weld, external supplier) for operators to record job progress. Each completed stage automatically moves to the next workflow stage.
• Stock Management Tools: Delivery recording, check-in/out of sheets and off-cuts, automated low stock alerts, off-cut allocation to nests and stock adjustments.
• Super Route Card Integration: Route card functionality built into the portal, eliminating the need for PDF-based processes. Operators can log manufactured parts, track progress by part and sheet and record fold details with audit history.

Extended Features:

• Job search by customer name and contract details.
• Job pages displaying purchase order information.
• Automatic PDF export of completed job details for future reference.
• Email notifications for ‘bought out’ parts requiring office action.

The impact

• Real-time visibility of job progress has been provided, across the factory floor.
• Efficiency has improved by digitising operator workflows and eliminating paper route cards.
• Stock accuracy has increased with automated tracking and low-stock alerts.
• Errors have been reduced by integrating job, operator and purchase order data into one system.
• Communication has been enhanced between office and operators with live updates and automated email alerts.
• A scalable platform has been created for continuous improvement and future automation.