Calderys, a global leader in high-temperature refractory solutions, supplies critical materials to industries like steel, cement, and petrochemicals. With operations across Europe, the Americas, and Asia—including the UAE—the company supports extreme industrial environments with tailored, high-performance products.
But as Calderys expanded globally, managing workflows across continents became slow, siloed, and manual. Teams re-entered data across disconnected systems like SAP, leading to errors, delays, and duplicate work. Leadership struggled to track progress, identify bottlenecks, or get reliable reports. Visibility was limited. Accountability was unclear. Decisions were based on lagging, inconsistent data.
To fix this, Calderys needed a system to automate tasks, sync critical data between platforms like SAP and Salesforce, and give leadership real-time insight into performance to operate at scale.
The Challenge: Disconnected Systems Slowing the Manufacturing Value Chain
As Calderys expanded its manufacturing operations globally, cracks began to appear across the end-to-end manufacturing value chain—from order intake and production planning to fulfillment and customer communication.
The core challenges weren’t isolated to a single plant or team. They were systemic:
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Manual data re-entry across core systems: Operational teams re-entered the same order and production data into systems like SAP every day. This introduced errors, version conflicts, and delays that rippled downstream into production planning and fulfillment.
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No real-time visibility into operational workflows: Leaders lacked a live view into order status, production handoffs, onboarding, and issue resolution. Bottlenecks surfaced only after customer impact had already occurred.
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Siloed systems and slow reporting cycles: Monthly reporting required stitching together data from spreadsheets, SAP, and other tools. By the time insights surfaced, opportunities to adjust staffing, production schedules, or customer commitments had passed.
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Unclear task ownership across operations: Work moved informally through email and spreadsheets, with no centralized system of accountability. Critical operational steps were missed, delaying production and fulfillment.
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Processes that didn’t scale with global manufacturing growth: As volumes increased, Calderys couldn’t scale core operational workflows without automating repetitive work and connecting systems across plants and regions.
In short, fragmented systems were limiting Calderys’ ability to operate as a connected, data-driven manufacturing organization.
The Solution: Connected, Automated Operations Across the Manufacturing Lifecycle
To modernize operations and strengthen the manufacturing value chain, Calderys implemented Process Street as a centralized workflow and orchestration layer, integrating it with SAP, Salesforce, Power BI, and Snowflake.
Rather than replacing existing operational technology, Process Street connected it—liberating data from siloed systems and turning it into actionable, real-time operational intelligence.
1. From Manual Data Re-entry to Integrated Manufacturing Operations
Before:
Order and customer data was manually copied into SAP each day, slowing execution and increasing the risk of errors that impacted downstream production and fulfillment.
After:
Process Street integrated directly with SAP, automatically syncing validated workflow data. This reduced administrative effort, eliminated duplicate entry, and ensured production systems always operated on accurate, up-to-date information.
Manufacturing impact:
Cleaner data flows improved production planning accuracy and reduced rework caused by incorrect or outdated inputs.
2. From Fragmented Tracking to End-to-End Operational Visibility
Before:
Operational teams relied on spreadsheets and email threads to track work across order management, production coordination, and customer updates. Leaders had no real-time view of progress or delays.
After:
Centralized workflows and live dashboards provided instant visibility into task status, bottlenecks, and overdue work across global operations.
Manufacturing impact:
Managers could proactively address issues before they disrupted production schedules or customer deliveries, improving throughput and reliability.
3. From Lagging Reports to Real-Time Manufacturing Insights
Before:
Monthly reports were assembled manually by reconciling data across multiple systems, delaying decisions on staffing, production capacity, and customer response.
After:
Process Street fed structured operational data into Power BI and Snowflake, enabling real-time reporting on order flow, operational performance, and issue resolution.
Manufacturing impact:
Leadership gained the ability to make faster, data-driven decisions that improved asset utilization, workforce allocation, and customer satisfaction.
4. From Informal Handoffs to Automated Task Orchestration
Before:
Tasks were assigned informally, often via email, with no clear ownership or enforcement. Steps were skipped, and accountability was unclear.
After:
Dynamic due dates, conditional logic, and automated task assignments ensured every step in the operational workflow was completed in the correct sequence by the right person.
Manufacturing impact:
Standardized execution reduced variability, improved process reliability, and supported consistent quality across plants and regions.
The Results: A Smarter, More Scalable Manufacturing Operation
By connecting systems and automating operational workflows, Calderys strengthened its manufacturing value chain end to end.
Key Outcomes
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Eliminated duplicate work: SAP integration removed manual data entry, reducing errors and freeing teams to focus on higher-value operational tasks.
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Faster, more confident decisions: Real-time Power BI and Snowflake reporting gave leadership immediate insight into operational performance.
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Full visibility across global workflows: Centralized dashboards replaced spreadsheets and emails, enabling proactive issue resolution.
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Scalable manufacturing operations: After a successful rollout in the UAE, Calderys began expanding Process Street globally across Europe, the Americas, and Asia.
From Process Automation to Smart Manufacturing Enablement
Calderys didn’t just automate workflows. They created a connected operational foundation that links enterprise systems, liberates manufacturing data, and delivers real-time insight across the organization.
What began as a solution to operational inefficiencies evolved into a smart manufacturing capability, one that supports consistent execution, improves productivity, and enables scalable growth across the global manufacturing value chain.
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Note: Our solution is powered by AWS and uses these AWS services: Amazon Bedrock, Lambda, SQS, API Gateway, S3, CloudFront, Elastic Beanstalk, WAF, ELB, RDS Multi-AZ, EC2 and ElastiCache for Redis. Process Street serves as the intelligent orchestration layer, where AWS AI services power the advanced reasoning and data processing that turns policies into workflows, and then enables workflow automations, intelligent document processing, and reasoning. Specifically, ProcessStreet’s GenAI capabilities are used to ensure that customers’ policies align with their workflows and that change governance mechanisms control how tasks are updated to achieve compliance in an automated manner. This creates a closed-loop system where AI directly triggers and guides actionable workflows.