Tier IV Pro: Unified Manufacturing Operations Platform

Replacing 12 Spreadsheets With One Executive Cockpit for a Mobile Command-Vehicle Manufacturer

App: Tier IV Pro | Industry: Manufacturing / Defense | Client: Confidential — custom mobile command vehicle and tactical trailer manufacturer (Montana, two production sites) | Company size: ~170 direct-labor employees, multi-site production, $50M+ annual revenue planning | Duration: Initial ~3-month build, ongoing partnership

Summary

A unified manufacturing operations and project-management platform combining real-time bay scheduling, financial goal planning, quality/IDQ tracking, and AI-assisted forecasting into a single executive cockpit.

The Challenge

Leadership was running operations across roughly a dozen disconnected spreadsheets, Monday.com boards, EasyProjects exports, IFS Cloud reports, and ad-hoc PowerBI dashboards. Site directors couldn't answer basic questions like 'are both production sites on pace to hit our 260K earned-hour goal?' without manually rebuilding the model every week.

Our Approach

• Built a custom capacity-ceiling and glide-path planner with EBITDA → earned-hours back-solver and headcount ramp simulator
• Layered an AI assistant (GPT-4 class) for natural-language querying, meeting summarization, IDQ narrative generation, and project-status risk analysis
• Integrated Microsoft 365 SMTP for scheduled notifications, Monday.com live sync, EasyProjects hours sync, and IFS Cloud connector
• Created a Babylon.js 3D plant/world engine for visual bay scheduling and floorplan analysis
• Implemented per-site (Combined / Site A / Site B) goal modeling with WebSocket-driven real-time updates
• Built IDQ + PDI penalty scoring engine, billing-milestone reconciliation, and schedule-bay collision detector

Outcomes & ROI

• ~12 — Tools Replaced: Consolidated standalone spreadsheets, Monday boards, and ad-hoc dashboards into one platform
• ~80% — Reporting Time Cut: Weekly executive prep went from a multi-day exercise to a live dashboard refresh
• 8–10 hrs — Saved Per Week: Nightly automated syncs replaced manual exports, freeing analyst time

Tracks 100+ active projects, ~170 direct-labor employees, and $50M+ in annual revenue planning across multiple production bays — all in one platform that previously required ~12 disconnected tools.

Technologies Used

React + TypeScript + Vite, shadcn/ui + Tailwind, Babylon.js (3D), Node.js + Express, Drizzle ORM + Neon Postgres, OpenAI GPT-4, Monday.com API, EasyProjects + IFS Cloud connectors

Key Takeaways

1. Manufacturing leadership doesn't need more dashboards — they need one cockpit that back-solves financial goals into operational reality
2. An AI assistant grounded in real operational data turns 'pull a report' into 'ask a question' and changes how often executives actually use the system
3. 3D bay visualization sounds like a nice-to-have until you watch a site director drag a project across two facilities and instantly see capacity conflicts

Frequently Asked Questions

How do you handle multi-site capacity planning?

We built a custom capacity-ceiling planner that models Combined / Columbia Falls / Libby independently, with a glide-path engine that back-solves EBITDA targets into required earned hours and headcount ramps per site.

How does the AI assistant access live operational data?

It queries the same Drizzle/Postgres data layer the dashboards use, so answers reflect the current state of projects, hours, and milestones — not stale exports.

What integrations are live?

Microsoft 365 SMTP, Monday.com sync, EasyProjects hours sync, IFS Cloud connector, Replit Object Storage for floorplans/documents, and SendGrid as an email fallback.

Related Services

• Digital Transformation
• AI Strategy
• Data Analytics

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