Serial-tracked production and warranty system for Zyena Engineers

Highsense Infotech built a factory management system for Zyena Engineers, a CNC machine manufacturer, covering BOM-driven work orders, component stock with goods receipt, purchase and vendor management, sales and dispatch, and serial-wise warranty tracking across every machine shipped.

The problem

A machine manufacturer sells a small number of high-value units, and each one stays the company responsibility for years after it leaves the floor. That makes the serial number the unit that matters: which components went into this specific machine, when was it dispatched, to whom, and is it still under warranty today.

Zyena Engineers was managing that across spreadsheets and memory. Build sheets were maintained per model rather than per unit, so two machines of the same model built months apart could not be told apart once a component was substituted. When a warranty claim came in, establishing whether the unit was still covered meant finding the dispatch paperwork.

Component stock had the same gap. Purchase orders, goods receipt and issue to production were recorded separately, so the shortage that stops a build was usually discovered on the shop floor rather than at planning.

What Highsense Infotech built

We made the serial the spine of the system. A work order is raised against a machine model, driven by its bill of materials, and the components consumed are recorded against that specific unit rather than the model in general. The finished machine carries a serial number that stays with it through dispatch, invoice and its whole service life.

Warranty is attached to the serial, not the customer. Each machine records its warranty duration in months and a calculated end date, so whether a unit is covered is a lookup rather than an archaeology exercise, and machines approaching warranty expiry surface before the claim arrives.

On the supply side, purchase orders run against vendors and goods receipt raises component stock, with every movement recorded. Production checks availability against the BOM before a work order is released, so a shortage appears at planning rather than halfway through a build. Sales, dispatch, invoicing and returns close the loop from the same records.

Inside the system

What changed

• ✓
  Any machine in the field traces back to the exact components that went into that unit, not just to its model.
• ✓
  Warranty status is a lookup against the serial instead of a search through dispatch paperwork.
• ✓
  Machines approaching warranty expiry are visible in advance, which turns an expiry into a service conversation.
• ✓
  Component shortages surface at planning, when a work order is checked against the BOM, rather than on the shop floor mid-build.
• ✓
  Purchase, production, dispatch and service all read from the same records, so the history of a unit is one story rather than four.

Technology