KAROVIČ ocelová výroba s.r.o.

About the client

KAROVIČ ocelová výroba, s.r.o. is a Slovak manufacturing company specializing in make-to-order steel production. It is implementing the “Iron & Steel 4.0” project — full digitization of steel manufacturing using artificial intelligence for analyzing production processes, prioritizing orders, planning production, sorting, and palletizing. It combines modern industrial technologies (Industry 4.0) with make-to-order metalworking for B2B clients, holds material stock across multiple warehouses, and ships finished products directly to customers.

The challenge

Make-to-order steel production with multiple branches and bills of materials requires extremely precise records of material, operations, and job status. Before Modulario, KAROVIČ dealt with:

• Inquiries, price quotations, sales orders, and jobs managed in different tools without ties to production
• Product bills of materials in Excel — without links to production operations and material items
• Warehouse operations (goods receipts, goods issues, transfer notes, reservations) without digital records or serial numbers
• Production operations and operation statuses tracked manually — no real-time view of job progress
• Attendance, shifts, and monthly employee reports in a separate spreadsheet
• Accounting (received and issued invoices, advance invoices, credit notes, complaints) disconnected from production

The solution

Modulario delivered a comprehensive manufacturing ERP with interconnected data structures focused on the specifics of make-to-order steel production:

• Commercial cycle — inquiries, inquiry items, price quotations, opportunities, jobs, job items, orders, order items (including purchase orders) with opportunity sources
• Production and bills of materials — production orders (main production), production operations, production order statuses, operation statuses, BOM, BOM items, operation BOM, ProdOrderLine material items, requisitions
• Warehouse and logistics — warehouses, branches, locations, stock items, items at locations, goods receipts, goods issues, transfer notes, transfer note items, stock movements, serial numbers, reservations, warehouse enumeration in order and job items, warehouse purge
• Delivery notes and complaints — delivery notes, delivery note items, complaints, complaint items, reverse operations
• Invoicing and finance — issued invoices, advance invoices, received invoices, received advance invoices, items of issued and received invoices, advance invoice items, VAT rates, payment methods, bank accounts, bank movements, exchange rate lists, constant symbols, document texts
• Attendance and HR — attendance, attendance records, attendance reports, daily and monthly reports, shifts, vacations, public holidays, downtime, employees, employee documents
• Directory — entities, entity directory, entity addresses, contacts, sectors, countries, address types
• Products and articles — products, article, article groups, product categories, parent product category, units, units of measure, document enumeration

AI for Industry 4.0

The goal of the Iron & Steel 4.0 project is to achieve full digitization of the production process and automation using artificial intelligence:

• Automatic setting of laser parameters based on material type and production operation
• AI production planning and order prioritization based on capacity, material availability, and deadlines
• Real-time status tracking — when defects occur, the system automatically adds products to the next production run without manual intervention
• Expected benefits per the project application: a twofold increase in productivity (approximately +€800k in annual revenue) and a reduction in machine error rate from 20% to 5%, shifting qualified employees to higher-value tasks (strategic purchasing, customer acquisition)