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Digital workflow transformation for a metal-processing services provider
The customer sought to streamline operations by digitalizing order management and the metal‑processing production workflow. Itransition delivered an integrated web application that supports efficient end-to-end management of the galvanizing lifecycle – from order intake to production and transportation.
25%
increase in production throughput
30%
improvement in labor productivity
Improved
decision-making
Engagement model
About the customer
Hubbell Galvanizing is a US-based company founded in 1925, providing galvanizing services for steel products to their clients. The company focuses on highly precise coatings with specific chemical and physical properties, using automation, testing equipment, manual inspection, and other tools.
Domain
Manufacturing, Construction
Company type
Private
Geography
USA
Years in business
100+
The challenge
As the company expanded and the number of its clients grew, it became increasingly important to implement a dedicated system for collecting and managing orders. The solution needed to support the full workflow – from the moment of initial order receiving to galvanizing and final transportation. By digitalizing workflows and introducing automation, the customer aimed to boost operational efficiency, unlock scalable growth, and enhance decision‑making through real‑time visibility into production activities.
The solution
At a glance
Itransition implemented a web application that supports the customer’s end-to-end galvanizing workflow, efficiently managing order intake, pricing, scheduling, and every production step, while ensuring each item meets the customer’s quality standards and providing reporting capabilities. The solution is based on Node.js and React and hosted in AWS.
System functionality
Functional modules
Order management
The system allows employees to create and manage orders for parts sent by end clients. Users can:
- Enter customer, carrier, and delivery information
- Add line items, specifying quantity, weight, and part types and assign production routes
- Track orders through predefined statuses
- Manually adjust automatically calculated prices if necessary
Pricing management
A centralized pricing module allows employees to:
- Set default prices for part categories
- Define customer-specific pricing rules
Scheduler
The scheduler provides a visual overview of all orders and line items. Employees use it to:
- Allocate orders or specific parts to production schedules
- Plan galvanizing work
- Plan shipping operations
Once planned, the corresponding items become available in the process workflow.
Shipping management
After production is complete, the system supports shipping operations:
- Creating shipping orders with support of full or partial shipment of items
- Generating printable shipping tickets with partially pre-filled information on customer, part/order, carrier, and employee responsible
Problem & additional work management
The system allows employees to:
- Register problems, such as dimensional errors or surface defects of the provided parts
- Track problem statuses
- Create and complete additional work orders linked to problems
- Record material usage and quantities that affect the final order price
- Sign off completed additional work
Reporting
- The system provides a galvanizing-focused production report with a detailed breakdown of operations by different criteria
Production process support
The system provides digital support and tracking for each stage of the customer's galvanizing process, seamlessly integrating racking, kettle processing, weight checking, quality assurance, and packaging. The solution features interfaces for recording parameters, updating statuses, and ensuring workflow consistency, with automated validations and workflow rules guiding each production step and prompting users to correct information when errors are detected.
Racking
- Selecting parts for racking
- Assigning rack type and number
- Recording rack weight
Kettle processing
- Displaying racks ready for galvanizing with pre-recorded weight
- Tracking weight of processed parts before and after galvanization
- Logging Kettle In time (galvanizing initiation) and Kettle Out time (item removal) and calculating the total dip time
Weight checking
- Recording total quantity of parts with total weight and weight by line item
- Calculating zinc pickup for each rack
- Performing price calculations (with optional manual adjustments)
Cleaning
- Displaying a list of all line items that have completed the weight checking step and are ready for cleaning with detailed information about the selected line item
- Marking the completion of the cleaning check process
Quality assurance
- Inspecting items marked as ready for quality assurance
- Confirming quality checks and routing items to the packaging step
Packaging
- Processing items marked as ready for packaging
- Confirming packaging status, marking line items as ready for shipping and routing them to the shipping module
Rejection process handling
- The system allows for rejecting a given production step if necessary and returning line items to previous workflow steps based on configured rules, offering predefined rejection solutions.
Order management
Galvanizing process
Future-proof your manufacturing processes with Itransition
The outcome
Itransition implemented an integrated digital workflow system, streamlining the customer’s metal-processing operations. The platform accelerated the end-to-end galvanization workflow, reduced manual input, and provided full visibility into each production stage. As a result, the customer achieved the following operational improvements:
01
25% increase in production throughput, driven by automation, real‑time data, and improved production flow
02
30% improvement in labor productivity, largely from reduced manual entry, fewer hand‑offs, and removal of rework
03
Improved decision‑making through real‑time visibility into order statuses, production loads, material usage, and bottlenecks
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