Optimizing inventory and multiprocess production orders with Synchro cards

At its plant in the province of Brescia (Italy), Oleodinamica Marchesini had been managing materials using a manual kanban system with magnetic cards and physical boards. 

Switching from a traditional “push” approach (planned based on sales forecasts) to a kanban system had already enabled a significant reduction in inventory. 

However, after months of gradual and consistent warehouse space reduction, the company had reached a standstill. 

This was due not only to the typical limitations of manual kanban and to management policies (kanban cards were not linked to individual boxes but to a layer of pallets, e.g., 12 boxes), but also to the presence of multiple production steps in flow (so-called multiprocess). 

With manual kanban, it was not possible to effectively link the various phases of the numerous production steps (e.g., laser marking). As a result, despite efforts to make these processes “pull” (triggered by actual consumption) production remained essentially make to stock. 

This led to the need for a solution that could overcome the standstill and continue the improvement journey toward a true pull system. 

After confirming that the software met their technical and functional requirements (intuitive interface, ease of use, ISO 27001 certification, and a modular, flexible pricing model), the company launched an initial implementation on a pilot line, not large in terms of item codes, but comprehensive in terms of process. 

Following this test phase, the company accelerated rapidly: in just a month and a half, KanbanBOX was adopted for all high-rotation items, which alone generate half of the company’s revenue. The usage was then progressively extended downstream, toward the warehouse, and upstream, to include low-rotation items as well. 

As Oleodinamica Marchesini optimized its processes and explored more of the software’s features, it discovered new functionalities and improvement opportunities that gradually expanded the original project. 

Among the key innovations was the use of Synchro cards, which (unlike traditional kanban cards) do not automatically trigger a replenishment order when consumed. Instead, they support a single-cycle procurement process. 

Using Synchro cards enabled the transition to a Make to Order (or Assemble to Order) model, making operations leaner and more responsive. 

One tangible result of this shift was the near-elimination of picking activities: once assembly is complete, operators can place the material directly on the shipping pallet, significantly reducing stock while still meeting order requirements within just a few days. 

Thanks to KanbanBOX, the company was able to improve operations, reduce lead time, and lower the need to stock items by eliminating unnecessary storage. 

• Inventory value: –€1 million (the space previously used to store only the top-selling item now accommodates half of the company’s revenue) 

• Annual inventory turnover: +1.5 rotations. The goal is to reach 8 by the end of the year, 10 by the end of the first quarter of the following year, and 12 in the medium term. 

• Lead time: –7 working days on average throughput time, despite already having a strong service level, with deliveries within 3 weeks. 

• Enablement of previously unthinkable Make to Order / Assemble to Order scenarios.