Apex Polyfoam: 100% factory visibility with real-time QR tracking
A manufacturing business had no visibility into what was happening on their production floor. Dispatch errors were discovered after delivery. Production planning was based on estimates, not data. Opsenova replaced all of that with a custom operations system built around their workflow.
“We finally know exactly what's happening on the production floor — in real time. Dispatch errors used to be a regular problem. Now they don't happen. The system pays for itself every month in the mistakes it prevents.”
The situation
No visibility. Errors discovered after delivery.
Apex Polyfoam manufactures foam products across a multi-step production floor. Before the system, tracking what was happening at each stage relied on manual registers and end-of-shift reports. By the time a manager saw the data, it was 8–12 hours old.
Dispatch was the most acute problem. Orders were picked manually from a paper pick list. Errors — wrong product, wrong quantity, wrong vehicle — weren't discovered until the delivery reached the customer or until a customer called to complain. By then, the truck had already left and rectification required a second delivery.
Production planning happened once a week, based on the sales team's estimates and a rough stock count. It wasn't wrong exactly — but it was always slightly off, leading to either over-production of slow-moving products or under-production of fast-moving ones.
What changed
Five operational changes. All in one system.
100% factory visibility
Every unit on the production floor is now tracked from the moment it enters production to the moment it leaves the building. Nothing moves without a record.
Real-time QR tracking
Each product carries a QR code that updates status — in production, in quality check, in warehouse, dispatched — the moment a staff member scans it. The production manager sees the live floor state on a dashboard, not in a report from yesterday.
Dispatch errors eliminated
Before the system, dispatch errors — wrong product, wrong quantity, wrong destination — were discovered after the truck had left. The new dispatch flow cross-checks every outgoing order against the confirmed pick list before a delivery note is printed. Errors are caught at the dock, not at the customer's site.
Automated dispatch routing
The system now generates optimised dispatch routes based on delivery locations, load weights, and vehicle availability — automatically. What previously required manual scheduling by a senior manager now takes 5 minutes.
Transformed production planning
Production planning used to start with the question 'what do we think we need?' Now it starts with actual order data, live material stock, and production capacity. The planning cycle is driven by real numbers, not estimates.
The approach
Built around how Apex Polyfoam actually works
The engagement started with a discovery session: two days mapping the production floor, understanding the dispatch workflow, and documenting exactly how decisions were made. No assumptions, no templates — just the actual workflow.
The system was then built in modules: QR-based production tracking first (the most acute pain point), then the dispatch verification flow, then the production planning dashboard. Each module was tested with the actual staff who would use it before the next was built.
The interface for floor staff is simple by design. A scan, a status update, a confirmation. It takes 15 seconds. It doesn't require training beyond a 30-minute walkthrough. That simplicity is deliberate — a system that staff don't use solves nothing.
Similar problems?
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