Industry: Machinery Manufacturing
Location: Oxfordshire, UK
Key Challenge: Transition from paper-based systems to modern digital operations
Solution: Implementation of Flowlens software
Cap Coder, a leading machinery manufacturer specialising in production line equipment for pharmaceutical, life & bio sciences, chemicals, and healthcare, faced significant operational inefficiencies due to outdated, paper-based systems. With the goal of modernising operations, improving cost tracking, and streamlining processes, Cap Coder turned to Flowlens for a comprehensive digital transformation.
Challenges Before Flowlens
Before adopting Flowlens MRP and MES software, Cap Coder relied heavily on manual processes and legacy software such as Sage, which created gaps in efficiency and transparency. As General Manager Paul Atherton, a key figure in Cap Coder’s transformation, explains:
“We were paper-based largely, and where we weren’t paper-based, we were using Sage… could easily identify massive gaps in efficiencies in terms of our office staff, planning, and forecasting.”
This lack of integration and automation meant that Cap Coder struggled with:
- Limited visibility into production costs, particularly labor expenses
- Inefficiencies in job scheduling and workflow tracking
- Data inaccuracies in bills of materials (BOMs)
- Time-consuming invoice processing, delaying cash flow
How Flowlens Delivered a Solution
Cap Coder implemented Flowlens, a UK-based subscription manufacturing software tailored for SME equipment and device manufacturers. The platform provided an integrated solution for sales, operations and cost tracking, workflow management, and financial oversight.
1. Enhanced Cost Tracking & Profitability Insights
One of the most significant improvements was gaining accurate visibility into production costs. Previously, Cap Coder could only track material costs but had no clear insight into labor expenses. With Flowlens, real-time labor tracking was introduced:
“We now know exactly what the machine costs, right down to the penny in every fitting and every minute spent on a job and on a step.”
This new level of financial oversight allowed Capcoder to conduct detailed cost analyses, uncover inefficiencies, and make data-driven decisions on pricing and production.
2. Improved Workflow Management
Before Flowlens, Cap Coder’s job scheduling was inefficient, with generalised work instructions and limited visibility into specific production steps. The introduction of structured digital workflows transformed this process:
“Now we are separating that list into its built components and going, ‘Here is a clutch assembly, these are the bits you need to start building it, and this is the first step.’”
This level of detail ensured that every process step was documented, eliminating gaps and improving overall productivity, right down to shop-floor work allocation and data capture.
3. Streamlined Data Integrity & Process Optimization
One unexpected benefit of Flowlens was its role in uncovering previously undocumented processes and inefficiencies. By digitizing and structuring Cap Coder’s workflows, hidden operational inefficiencies surfaced:
“Now because we’re sitting there building the process digitally, we’re actually uncovering gaps… things like ordering screws in the correct length instead of manually modifying them.”
This attention to detail enabled Cap Coder to optimise procurement and manufacturing, reducing unnecessary modifications and waste.
4. Seamless Integration with Financial Systems
Flowlens seamlessly integrated with Xero, replacing Sage and resolving Cap Coder’s long-standing invoicing challenges:
“Prior to Flowlens, invoice processing had duplicate data entry, required additional staff, and delayed cash flow. Now, within a few clicks, we have an invoice through the system out to the customer with the correct due date, and it is totally seamless.”
This improvement allowed Capcoder to reduce administrative overhead, improve cash flow, and allocate resources more effectively.
Change Management & Lessons Learned
Atherton emphasizes the importance of data preparation when implementing new systems:
“The biggest advice I would give is to really look into what your business is doing right now and the data that it’s got… It takes a surprisingly large amount of time to fix data. We had 48,000 BOMs, and it took weeks and weeks to realign them.”
This insight underscores the importance of allocating sufficient time and resources to ensure a smooth transition to digital systems. Flowlens provide guidance and templates to help streamline this process.
The Flowlens Customer Experience
Beyond the software’s capabilities, Flowlens’ change management expertise and customer service played a pivotal role in Cap Coder’s successful transition. The close collaboration and tailored support provided by FlowLens made the implementation process smooth and adaptable:
“Flowlens didn’t just press on us that we should fit within their system. They worked with us to fit the system around our needs and they’ve been really supportive throughout the journey, and receptive to feedback and ideas.”
The strong communication and industry expertise of Flowlens ensured that Capcoder received a tailored manufacturing and operations solution, not just a one-size-fits-all system with too many compromises.
Key Results & Business Impact
- Improved Cost Visibility: Full tracking of material and labor costs for each product
- Enhanced Productivity: Structured workflows and shopfloor instructions reduced inefficiencies and manual errors
- Stronger Financial Management: Seamless integration with Xero streamlined invoicing and cash flow
- Optimized Resource Allocation: Reduced administrative burden enabled hiring of more engineers to boost production
Conclusion
The implementation of Flowlens at Cap Coder showcases how a modern, integrated manufacturing solution can revolutionise operations for SME equipment manufacturers. By replacing outdated processes with automated workflows, real-time cost tracking, and seamless financial integrations, Flowlens has empowered Cap Coder to operate with greater efficiency, accuracy, and profitability.
For any device, equipment or machinery manufacturing SME seeking to modernise and optimise its operations, Flowlens MRP, CRM & MES proves to be a powerful, adaptable solution that delivers real, measurable business benefits.
