Microcare Solar Energy: Optimising Solar Equipment Manufacturing with Arcflow

Company Overview

Microcare Solar Energy is an established solar equipment manufacturer with over 35 years of operational experience. The company manufactures a broad portfolio of solar and energy-related equipment entirely in-house. The current production range comprises 36 distinct products, including inverters, MPPTs, pump controllers, EV chargers, and related solutions.

Manufacturing operations are supported by complex, multi-level bills of materials (BOMs) incorporating numerous sub-assemblies such as PCBs, wiring, metalwork, transformers, fasteners, and packaging. As a result, accurate stock control and end-to-end traceability are critical to ensuring effective and reliable production.

Challenge

Prior to implementing Arcflow, Microcare faced operational challenges across planning, procurement, and stock management. Key challenges included:

• Limited forecasted stock visibility: Insight into raw materials, sub-assemblies with complex multi-level BOMs, and finished goods forecasted stock levels was difficult due to large stock movements across sales orders, production, and procurement.

• Complex procurement cycles: Managing multiple suppliers per component, each with unique MOQs, part numbers, unit conversions, and price breaks, created complex and time-consuming workflows.

• Manual data capture and ordering: Reliance on manual processes for complex order planning increased procurement cycle times and operational effort.
  
  

Solution

Microcare implemented the Arcflow system 18 months ago, gaining a solution tailored specifically to its manufacturing operations. The key Arcflow modules contributing to the project’s success include:

• Warehouse analysis AI: Provides real-time visibility into current and forecasted stock levels, enabling the team to anticipate material shortages and proactively address potential production disruptions.

• Centralised order plan: Acts as a single source of truth for RFQs and purchase orders, streamlining complex procurement workflows involving multiple suppliers. The interconnected system automates supplier selection, supplier conversions, MOQs, and price-break calculations, while also managing document generation, capturing supporting records, and initiating all procurement-related email correspondence on behalf of the purchasing team.
  
  

Results

• Reduced procurement cycle times: End-to-end procurement cycle times have been reduced by up to two months in some instances through the use of the Order Plan functionality.

• Increased employee productivity: Procurement tasks that previously required two employees can now be initiated by the Production Manager in as little as 10 minutes using Arcflow automation, with the Stores Controller completing the process seamlessly.

• Improved stock control: Enhanced management of raw materials, sub-assemblies, and finished goods ensures optimal stock availability for both sales orders and production plans.
  
  

Customer Quote

“Arcflow has been a strong fit for a manufacturing business like ours. The biggest wins have been in planning and procurement cycles, the system helps us avoid crises before they happen and keeps operations running smoothly.”
— Ray Parker, Director & Shareholder, Microcare