How The CTD Group Improved Reporting Accuracy by 41.1% and Increased ROI by 119%

Manufacturing plans depend on assumptions about machine time, setup duration, process flow, and job cost. When planned ERP data and actual shop floor performance remain separated, quoting, scheduling, and profitability decisions can be based on incomplete information.

The CTD Group faced this issue across a large facility with CNC machining, welding, painting, and workgroup centers. Discrete systems created disjointed information and siloed operations. The public CTD Group Success Story reports a 41.1% increase in data reporting accuracy, a 119% increase in ROI, and automated weekly reports delivered to the CEO.

Key takeaways

• Data reporting accuracy increased by 41.1%.

• ROI increased by 119%.

• The CEO received automated reports every week.

The gap between planned data and actual production

ERP systems contain essential business information such as orders, routings, standards, costs, and schedules. Their accuracy depends partly on whether planning assumptions reflect actual machine and process performance.

The CTD Group had large gaps between planned ERP data and actual machine data. Separate systems created information silos across business operations. SensFlo’s guide to production scheduling accuracy explains how stale availability assumptions, cycle time variance, setup overages, and missing shop floor feedback can weaken schedules and forecasts.

Monitoring a multiprocess manufacturing environment

The CTD Group monitored CNC machining, welding, painting, and workgroup centers that supported multiple process steps. This mattered because the company’s production flow extended beyond a single machine type.

The implementation also included real time CPQ to compare planned and actual time. CTD migrated its product catalog from Google Sheets into a data set connected with machine data and ERP information. Real time alerts were established for setup overages.

This created a more complete view of how quoted or planned work compared with actual execution. It also gave the team a way to identify setup time that exceeded expectations while the information could still support action.

Connecting operational data with commercial decisions

CPQ, planned versus actual tracking, machine data, and ERP information all influence the economics of a job. A quote depends on expected time and cost. Profitability depends on what the operation actually requires.

By bringing these data sources closer together, CTD could improve the accuracy of reporting used for management and commercial review. Setup overage alerts also gave the team a specific signal when actual performance moved beyond the plan.

FloControl Premier supports MES and ERP integration, job tracking, and custom API access for manufacturers that need machine data connected with enterprise systems. The CTD implementation also included real time job profitability and machine learning capabilities.

What the published results mean

The 41.1% increase in data reporting accuracy indicates that CTD improved the reliability of information moving through its operation. Automated weekly reports to the CEO also created a consistent executive view of performance.

The public case study reports a 119% increase in ROI. It does not publish the detailed ROI formula, investment amount, or financial period, so the article should preserve the reported figure without adding unsupported calculations.

From a business perspective, more accurate reporting can support better quoting, scheduling, setup management, and resource allocation. Those decisions affect both top line revenue and bottom line savings. The exact financial contribution of each decision requires internal CTD data that is not included in the public case study.

What other manufacturers can learn from The CTD Group

The CTD Group shows that machine monitoring can support more than equipment visibility. When actual process data is connected with planning and product information, it can improve the accuracy of business decisions made around production.

A manufacturer with siloed systems can begin by identifying the largest difference between planned and actual performance. Setup time, job duration, machine availability, and reporting accuracy are common starting points. The next step is to connect measured shop floor data with the systems that use those assumptions.

Frequently asked questions

How did SensFlo improve reporting accuracy for The CTD Group?

SensFlo connected monitoring across CNC machining, welding, painting, and workgroup centers. CTD also used real time CPQ to compare planned and actual time, migrated its product catalog from Google Sheets into a data set connected with machine and ERP information, and added alerts for setup overages.

What results did The CTD Group report?

The public SensFlo case study reports a 41.1% increase in data reporting accuracy, a 119% increase in ROI, and automated weekly reports delivered to the CEO. The public page does not provide the detailed formula or measurement period behind the ROI result.

Why should manufacturers compare planned and actual production time?

Comparing planned and actual time shows whether routing standards, quotes, schedules, and setup assumptions match shop floor performance. The difference can reveal inaccurate standards, recurring setup overages, machine availability issues, or process steps that require more time than expected.

How does machine data support ERP accuracy?

Machine data provides measured information about run time, idle time, downtime, cycle performance, and process duration. When connected with ERP records, it can help manufacturers update planning assumptions using actual production behavior. ERP remains the business system, while machine monitoring supplies current shop floor evidence.

Manufacturers can model potential production value with the ROAI Calculator, review FloControl Premier, or contact SensFlo.