Last updated: July 2026

FireFlight for Manufacturing: One System for the Whole Floor

Run production, inventory, work orders, and job costing on one platform. BOMs update everywhere at once. MRP fires before a shortage reaches kitting. Job costing you can see in real time. Built for teams of 20 to 500 employees. Live in weeks, not months.

FireFlight is the operational system manufacturers migrate to when spreadsheets and aging tools stop keeping up. It runs BOMs, MRP inventory, work-center routing, serialization, and job costing on one platform, built for industrial teams of 20 to 500 employees. One engineering change reaches every product, and most deployments complete in weeks, not months.
FireFlight Project Overview Dashboard showing production project status and budget for a manufacturer

Why does production drift from the plan?

In a growing plant, engineering rebuilds a BOM by hand for every configured order, a shortage surfaces at kitting, the whiteboard schedule reflects hope more than reality, and no one can see profit by product line. Each gap costs hours, material, and margin.

The root cause is not effort. The work lives in separate tools that never talk to each other, so a change in one place never reaches the next. The fix is a single system where the quote, the BOM, inventory, the schedule, and the invoice share the same data. That is the FireFlight operational platform.

What does FireFlight run on the plant floor?

FireFlight is assembled from modules that map to how a plant actually works, from the quote through routing to job costing. Each one shares the same data, so a change in engineering reaches inventory, the schedule, and the invoice without a re-entry step.

  • Product and Component Templates: Full BOM, routing, and costing per product. Shared subassemblies live as reusable components, so one engineering change reaches every product that uses it.
  • MRP-Driven Inventory: Material requirements calculated from confirmed orders and schedules across every product, so procurement fires before a shortage reaches kitting.
  • Digital Work-Center Routing: Each product routes through cutting, machining, welding, assembly, and QA, with instructions driven by real material and capacity.
  • Serialization and QA: Motors, drive components, and critical parts get serialized and tied to QA events, so a field issue traces back in minutes.
  • Parameter-Driven Quoting: Sales generates accurate cost and lead time from the customer configuration, without waiting on engineering.
  • Template-Driven Job Costing: Actual labor and material attach to every job as it runs, so profit by product line becomes visible.
FireFlight project template library with conveyor system and component families for build-to-order manufacturing

The modules are already built and tested, so the work is configuration, not a rebuild from zero. That is why most FireFlight systems go live in weeks, not months, with a focused build running about 2 to 4 weeks. PCG configures your BOMs, routing, cost centers, and reports for your specific plant before go-live, and existing work order and inventory data migrates as part of the deployment.

Want to see FireFlight running on your kind of operation? Book a live demo and the team walks your BOMs, inventory, work orders, and job costing through the system, then maps what a deployment on your floor would look like.

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What changes when a plant runs on one system?

A conveyor manufacturer running ten product lines across two plants moved off spreadsheets and a whiteboard onto FireFlight. Here is what changed.

  • End-of-day BOM rebuilds stop. Engineering-controlled templates carry the BOM, routing, and costing, and one change reaches every product that uses the shared part.
  • Shortages stop surfacing at kitting. MRP calculates requirements from confirmed orders and fires procurement before the gap reaches the floor.
  • The schedule reflects reality. Work-center routing runs on real material availability and capacity instead of a whiteboard.
  • Product-line profit becomes visible. Job costing attaches actual labor and material to every job as it runs.
  • Migration happens without stopping production. PCG moves your data and workflows in stages, and most systems go live in weeks, not months.

Can you just ask your plant a question?

Yes. When you need something specific, you do not build a report or export a spreadsheet. You ask FireFlight in plain English, and it returns the matching records, ready to export. The built-in advisor is part of every deployment, so no one needs SQL or a report builder to get an answer.

Ask your operation

Answers from your live data, in plain English

Type the question, get the records. No report builder, no export scramble.

"What do I need to reorder this week, with levels and quantities?"
"Show me inventory that has not moved in 30 days."
"Which work orders are behind schedule, and what are they waiting on?"

Every answer comes with Show SQL, CSV, and PDF export on the result.

FireFlight AI advisor answering a plain-English question, listing the inventory to reorder this week with levels and quantities

Is FireFlight built for your operation?

FireFlight fits US manufacturing and industrial teams of roughly 20 to 500 employees, especially build-to-order and configured-product shops. It is built and supported by Phoenix Consultants Group. This is you if:

  • You build configured or made-to-order products, and every order rebuilds a BOM by hand.
  • Shared components change, and the update never reaches every product that uses them.
  • Shortages surface at kitting instead of in planning, and rush orders keep rewriting the schedule.
  • Profit by product line takes a manual scramble, and your data still sits in Access, FoxPro, or Excel.

FireFlight is developed and maintained exclusively by Phoenix Consultants Group. Since 1995, across 31 years, PCG has built and rescued more than 500 operational systems in over 45 industries, migrating Access, VB6, FoxPro, and Excel workflows onto modern .NET Core without stopping production. The same engineers who configure your plant keep supporting it as you grow.

Questions about FireFlight for Manufacturing

Does FireFlight handle build-to-order and configured products?+
Yes. Product and component templates carry the BOM, routing, and costing, and parameter-driven quoting turns a customer configuration into an accurate cost and lead time without waiting on engineering.
Can it run MRP across several products and warehouses?+
Yes. Material requirements are calculated from confirmed orders and schedules across every product and warehouse, so procurement fires before a shortage reaches kitting.
What happens when we change a shared component?+
The change propagates. Shared subassemblies live as reusable components, so one edit reaches every product and open work order that uses them, instead of a manual rebuild per product.
Can we trace a serialized part back to its QA history?+
Yes. Motors, drive components, and critical parts are serialized and tied to QA events at each stage, so a field issue resolves from serialized data in minutes.
How long does it take to run on our floor?+
Most systems go live in weeks, not months. A focused build runs about 2 to 4 weeks, depending on how many product lines and modules you need.
Do we have to stop production to migrate?+
No. PCG moves your data and workflows in stages, so the plant keeps running while FireFlight comes online.
Can we ask FireFlight questions in plain English?+
Yes. FireFlight has a built-in advisor that answers questions about your live data without a report builder or SQL. Ask what to reorder this week, which work orders are behind, or what inventory has not moved, and it returns the matching records ready to export as CSV or PDF.

Every configured order your team rebuilds by hand is time and margin the plant cannot get back. FireFlight puts the BOM, inventory, routing, and job costing on one system, and PCG stands it up without stopping production. Most systems go live in weeks, not months.

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Allison Woolbert
Allison Woolbert
Principal, Phoenix Consultants Group  |  Developer, FireFlight Data Systems

PCG founded 1995. 500+ applications built across 31 years, many in regulated and operations-critical environments. FireFlight is the platform built from that body of work. When you contact PCG, Allison is the person who answers.

FireFlight Data Systems is a product of Phoenix Consultants Group. PCG founded 1995. All system configurations are custom-built for each deployment. Implementation timelines, module availability, and integration scope vary by organization. Contact PCG directly to discuss requirements specific to your operation.