Transforming Operational Efficiency in the Galvanizing Industry Through Integrated Software Solutions

Galvanizing is a crucial industrial process that involves coating steel materials with zinc to protect against corrosion — essential for the construction industry and government infrastructure projects. Given the nature of the work, galvanizing operations require accurate and timely reporting of production processes, material usage, and delivery schedules to maintain quality standards and meet client expectations.

The galvanizing industry faces unique challenges in production management, data collection, and operational reporting due to its complex processes and multi-department coordination.

Case Study : Multinational Galvanizing Company 

One of CS Software's customers is a multinational firm headquartered in Austria, specializing in steel galvanizing by coating steel with zinc to prevent rust. Its primary market includes construction companies and government infrastructure projects, demanding reliable anti-corrosion treatment.
The Indonesian branch was the first to implement a customized system in 2020, integrating production, material usage, delivery, and purchasing data. Due to the success in Indonesia, now, the system is also being used in the Middle East branch. 
Data collection presented significant obstacles before digital solutions were introduced. The process was labor-intensive and error-prone, with frequent miscommunication between departments. This slowed down data acquisition and impacted the accuracy of reports.
To address these issues, CS together with the customer are aimed to:
Integrate all production, material, delivery, and purchasing data into a centralized system.

• Enable real-time reporting and operational visibility.
• Reduce manual workload and optimize staff allocation.
• Improve decision-making speed and accuracy through digital dashboards.
• Integrate operational data with the company’s existing accounting system.

Implementation of CS Software : 

The implementation involved detailed examination and design tailored to the company's specific galvanizing processes. Emphasis was placed on integrating data collection seamlessly with existing workflows and improving decision-making through real-time reporting.

The CS system was customized specifically for the galvanizing line to cover zinc coating and anti-rust processes. It integrated with existing accounting software to maintain financial consistency. 

CS Software is fully implemented in Incoming material process, Weighing, Blasting, Take-On, Hot-Dip Galvanizing in the kettle process, Take-off, Scaling until deliveries.

The solution also used QR codes scanners, digital weight machines and tablet pc  to collect data, replacing paper and manual entry tasks. 

Results & Impact 

Since the CS Implementation in 2020, CS customer achieved :

• Data collection and reporting became significantly more efficient through streamlined integration and real-time data access. Centralized data from multiple divisions improved accuracy and operational decision-making while reducing manual work.
• The system integrates directly with the company’s existing accounting software, allowing seamless data flow between production, purchasing, and finance departments. This integration eliminates the need for duplicate data entry, reducing errors and saving time. By linking material usage and delivery data to accounting records, the company gains better financial visibility related to production costs and outstanding deliveries. This connection helps generate precise reports that combine operational and financial information, providing valuable insights for budgeting and planning.
• The company initially used software limited to the kettle and scaling stages only, which provided incomplete insights into the entire production workflow. The new tailored system covers the full production process.
• By expanding software coverage, each step from raw material intake to final delivery is monitored and recorded. This holistic approach allows for better control of production quality and timing, crucial for the company’s clients in construction and government projects.