Kuyer Metaal

Kuyer Metaal: flow-based order release in metal fabrication

How a high-mix metalworking shop stopped ERP orders flooding the shop floor, brought WIP under control and improved delivery reliability.

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Kuyer Metaal metalworking shop floor

Goal

Less work waiting.
More reliable delivery.

The result: WIP under control, more predictable lead times, and a production team that works with clarity instead of firefighting.

What Kuyer Metaal wanted

Kuyer Metaal, a Dutch manufacturer in Nijkerk, makes complex custom parts in high-mix, low-volume metalworking. To support its growth, it wanted to modernize planning and the shop floor. The goal: less work waiting between workstations, more accurate planning, and reliable process times from better time registration.

About Kuyer Metaal

Founded in 1971, Kuyer Metaal is a high-mix metalworking specialist with around 80 employees. Operating from an 8,000 m² facility, it makes a wide range of custom metal products, from single pieces to series of up to 1,000 items.

Growing demand and more complex production flows called for one connected system that brings structure, visibility and predictability to the shop floor.

Challenges

Orders released too early.
Unpredictable lead times.

Before 24Flow, Kuyer Metaal ran into these problems:

01

Orders straight from the ERP

Orders went straight from Exact Online to the shop floor. WIP piled up, and lead times grew long and unpredictable.

02

No production system

Planning ran on spreadsheets and manual coordination, so setting priorities was hard.

03

No reliable process times

Without accurate time registration, planners had no reliable process times to plan with.

04

WIP buildup and bottlenecks

Without controlled order release, workstations were overloaded and the flow was hard to manage.

05

No real-time visibility

The office could not see progress. Decisions came late, and the follow-up calls never stopped.

Solution

Release only what can flow.
See it all in real time.

To bring structure and visibility to production, Kuyer Metaal chose 24Flow for shop floor control and production scheduling, connected to Exact Online.

The office and the shop floor now work from one view, from order release to the finished part.

Order release and WIP control

24Flow releases work based on capacity. Instead of flooding the shop floor with ERP orders, Kuyer Metaal releases only what can flow, so WIP stays low and lead times become predictable.

Time registration

Operators register real process times digitally, so planners get accurate data for costing, capacity planning and continuous improvement.

Shop floor visibility

Team leaders see progress, bottlenecks and workstation load in real time and act early.

Connected systems

24Flow exchanges order data with Exact Online, Kuyer Metaal’s ERP. Alongside 24Flow, Kuyer Metaal runs BizBloqs for warehouse movements and Oseon (TRUMPF) for machine status.

Impact

Working ahead,
not behind.

With 24Flow, Kuyer Metaal moved from firefighting to structured, predictable flow. Kuyer Metaal now has a digital base that grows with the business, and a production process it can rely on.
6
months

of backlog caught up at Kuyer Metaal

“Our planning was always behind schedule. With 24Flow, we were finally able to work ahead and catch up on six months of backlog.”
Marcel Koopman · Operations Manager, Kuyer Metaal

Better delivery reliability

Controlled order release keeps less work waiting between workstations.

Accurate process times

Real-time registration improves planning and cost calculations.

Clear priorities

Teams work from one priority list instead of constant rescheduling.

One view for office and shop floor

Everyone sees progress in real time, from order release to shipping.
24

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ERP orders flooding your shop floor?
Release only what can flow.

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