Leading Custom LED Lighting Manufacturer

A Brooklyn-based custom LED lighting manufacturer producing bespoke fixtures for hospitality, workplace, and residential projects faced significant operational challenges inherent to high-mix, low-volume electronics assembly. With over 1,000 SKUs and the capacity to produce more than 14 different fixture types in a single day — all built to order by hand — the operation relied on paper-based work instructions and manual booklets for UL compliance labels that operators populated themselves. Tracking labor time and inventory across this level of product complexity was unwieldy and error-prone, threatening the manufacturer's aggressive 10-day lead time commitment.

The manufacturer implemented Tulip's no-code manufacturing app platform, integrating it directly with their NetSuite ERP to create a connected shop floor. Using Tulip's app editor, the Production Manager built dynamic digital work instructions that automatically pull the relevant bill of materials and generate SOPs from NetSuite data whenever a new work order is created. This IoT-enabled approach means each workstation receives the correct assembly steps and component specifications for the active order in real time — replacing the static paper booklets operators previously had to navigate manually. The Tulip–NetSuite integration eliminated the data gap between back-end inventory and production planning systems and the physical assembly floor.

The Tulip deployment measurably improved information flow and operator productivity across the assembly operation:

• Eliminated manual document lookup: Work orders now automatically surface the correct BOM and SOPs from NetSuite, removing a key source of assembly errors.
• Improved onboarding speed: New builders with no prior Tulip experience were able to use the system immediately, reducing ramp-up time on the floor.
• Increased production visibility: Real-time data exchange between Tulip and NetSuite added a layer of shop floor visibility that the ERP alone could not provide.

Qualitatively, the shift reduced supervisor intervention during assembly and gave the production team greater confidence managing 14+ fixture types per day against a 10-day lead time.

• ERP integration is a force multiplier: Connecting digital work instructions directly to NetSuite meant operators always had accurate, order-specific data — no manual document selection required.
• High-mix environments need dynamic instructions: Static paper SOPs break down when SKU counts exceed what operators can reliably manage; order-driven digital guidance is the practical alternative.
• Low-code tools lower the adoption barrier: Tulip's interface was accessible enough for new operators to use without dedicated training, which matters when onboarding in a craft assembly environment.
• The Production Manager as builder: Empowering operations staff to build and modify apps without IT dependency accelerated deployment and kept the solution aligned with floor realities.