Case Study: Saturn Industries achieves over 90% on-time delivery with WM Synergy's Protected Flow Manufacturing (PFM)

For Saturn EDM, Protected Flow Manufacturing™ Improved On-Time Delivery from 50% to over 90% in a few weeks without extending leadtime

Saturn Industries, a manufacturer of EDM electrodes and tooling, was struggling with on-time delivery—running about 50–60%—because a dated ERP and FIFO scheduling led to growing backlogs, frequent customer escalations and ISO risk. To fix this, Saturn engaged WM Synergy and implemented Protected Flow Manufacturing (PFM) scheduling/shop‑floor execution software.

WM Synergy’s PFM replaced static schedules with real‑time execution and predictive simulations that prioritize work that cannot wait. In weeks Saturn’s on‑time delivery climbed to 71% (Dec 2017), 78% (Jan 2018) and 89% (Feb 2018), ultimately exceeding 90%—all without extending lead times; the backlog shrank, customer inquiries dropped, and one person now manages scheduling.

Saturn Industries

Rory Lee

Business Development Manager