Custom software development case study

NW Flow Custom Workflow Automation System for Manufacturing

From Manual Chaos to Smart Automation on the Factory Floor

Visit website ↗Discuss a similar project

Intention: To develop a centralized job tracking system that automates on-demand textile production, integrates with NetSuite, and provides real-time visibility across all workflow stages.

Technologies used: React, Tailwind CSS, NestJS, MySQL, PHP, Laravel, REST API, NetSuite Integration, QR Code/IoT Tools

People Involved: 1 PM, 2 Backend Developers, 1 Frontend Developer, 1 QA

Timeframe: 3 months (MVP stage): Discovery & Architecture Backend & API Development Frontend Implementation QA & Internal Testing Client Review & Handover

Prehistory of the development

Before NW Flow, the Northwest Group — a large U.S.-based textile manufacturer — relied on paper sheets, Excel files, and fragmented manual communication to manage daily production. This approach caused frequent mistakes, slow batch coordination, and costly rework. As production scaled, tracking each job’s progress became nearly impossible. These challenges led to the idea of building a centralized, automated job tracking platform that could connect every department, ensure real-time visibility, and eliminate manual chaos.

Our Approach From fragmented communication to a connected digital ecosystem

To address the inefficiencies in Northwest Group’s on-demand textile production, our team built NW Flow — a web-based job tracking system designed to fully synchronize with NetSuite via API. The system replaces paper and Excel workflows with an automated process that tracks every production stage — Review → Setup → Print → Transfer → QC → Ship — in real time. By implementing QR-code tracking, every garment and job bag receives a unique identifier, enabling instant status updates and traceability across departments. This eliminates the need for manual transcription, reduces reruns, and provides management with full operational transparency.

The solution also includes a mobile-optimized scanning interface for tablets and phones, allowing floor operators to update job progress directly at their stations. Through a role-based access model, each department (DTF, Dye Sublimation, QC, Shipping) interacts with a tailored dashboard showing only relevant tasks and actions. These features, combined with automated exception handling and real-time synchronization with NetSuite, transformed a multi-step manual workflow into a connected digital ecosystem — cutting down delays, reducing human error, and giving leadership complete control over production visibility.

NW Flow Custom Workflow Automation System for Manufacturing

Custom workflow automation system to meet internal production needs

NW Flow is a tailored internal system that digitizes every step of the production workflow. It starts by importing orders from NetSuite, allows sorting into production types, applies QR-coded job bags, tracks each stage (Setup, Print, Transfer, QC, Shipping), and logs exceptions for traceability. With mobile-ready pages, workers simply scan and proceed — no need to fill in paper reports or communicate manually across shifts.

Key features of NW Flow:

Real-time NetSuite integration – automated import of production orders with validation and manual confirmation.

QR-based tracking system – all job bags and garments get QR codes for easy scanning at each stage.

Role-based dashboards – separate interfaces for QC, Managers, Setup team, Transfer, and Shipping.

System functionality includes:

Manual order confirmation interface for managers
Visual status tracking and progress filtering
Custom grouping logic for dye sub jobs
Exception logging and rerun routing

Mobile scanning interface
QR code print generation
Role-based restrictions for reruns
Sync logs and system health monitoring

The upcoming roadmap includes

Advanced analytics dashboards to visualize production trends, identify slowdowns, and measure throughput in real time.
Employee efficiency metrics for evaluating workload distribution and performance optimization.
Enhanced NetSuite synchronization, including inventory data and real-time material availability checks.
A dedicated mobile app with offline scanning capabilities for use in areas with unstable connectivity.

Centralized order flow = zero data loss

One source of truth across all departments thanks to NetSuite sync and confirmed orders only flowing downstream.

Mobile-first execution = smooth factory workflow

Workers don’t need to type or write — they scan, move, and produce. Real-time visibility improves productivity and accountability.

Key team members

Sergii

Magento 2 Full-Stack Developer

Development

Iryna

Senior Laravel / PHP Developer

Development

Results of the NW Flow implementation

NW Flow replaced all paper-based workflows, reduced rerun errors by 60%, and gave full transparency over job progress to every department. The system is now the backbone of their on-demand production model. Managers report faster turnaround, fewer bottlenecks, and a dramatic drop in miscommunication between printing and shipping teams.