Ighama Tractor and Forklifts: A FireFlight Transformation Story

Ighama Tractor and Forklifts began as a family-owned forklift manufacturer in the Midwest, producing a few dozen forklifts per month for local warehouses. Their forklifts became popular for their durability and affordability, and demand quickly grew beyond the local region. To meet this demand, Ighama invested in multiple manufacturing plants across the country, established regional distribution centers, and partnered with hundreds of dealer locations.

With rapid expansion came unexpected complexity. Inventory management became chaotic. Plants and dealers tracked forklifts and spare parts independently, often resulting in stockouts at high-demand dealers while other locations sat on excess inventory. This led to frustrated customers, lost sales, and unnecessary storage costs.

Shipping inefficiencies multiplied. Emergency shipments, last-minute transfers, and inconsistent logistics caused freight expenses to soar and delayed deliveries. Dealers were forced to compensate by keeping extra stock on hand, tying up capital unnecessarily.

Manufacturing inefficiencies emerged as well. Some plants overproduced low-margin models, while others struggled to meet demand for high-performing forklifts. Management had no clear visibility into which plants were performing best or where bottlenecks existed.

Financial operations were equally challenging. Revenue, costs, and margins were scattered across plants and dealers, making consolidation difficult and strategic decision-making almost impossible. Maintenance parts were inconsistently tracked, resulting in downtime for customers when replacement parts weren’t available promptly.

Leadership recognized that continuing with spreadsheets and disconnected ERP systems would hinder growth and profitability. Ighama needed a system that could unify inventory, finances, and production, while providing actionable insights and optimizing operations across all locations.

FireFlight Solution

FireFlight addressed Ighama’s challenges by providing a unified, data-driven platform:

Single Source of Truth:Consolidated inventory, sales, production, dealer data, and financials, ensuring everyone in the company worked from the same data.

Real-Time Event Pipeline: Captured forklift sales, parts usage, production completions, and transfers as they happened, allowing immediate visibility.

Calculation Engine:Applied consistent costing, margin calculations, and financial roll-ups across all locations, ensuring accurate reporting.

 Scenario Engine: Simulated production adjustments, inventory reallocations, and dealer demand scenarios to identify the most efficient operational strategies.

Transfer Optimizer:Recommended low-cost shipments from plants to dealers or regional warehouses, reducing emergency freight and minimizing shipping costs.

Role & Workflow Controls:Dealer managers approved inventory requests; plant managers monitored production efficiency; finance validated roll-ups and approved exceptions.

Reporting & Dashboards:Enabled drill-down visibility from dealer → regional warehouse → plant → HQ, allowing leaders to make informed decisions at any level.

Build/Deploy & Migration Pipelines:Ensured safe deployment of business rules and seamless integration of legacy plant and dealer data.


Problem-Solution Mapping

 
Problem
FireFlight Solution
Dealer stockouts or 
overstock
Unified inventory + transfer optimizer ensures dealers receive 
forklifts and spare parts efficiently.
High shipping costs
Scenario engine evaluates plant-to-dealer transfers vs. 
expedited shipping to minimize costs.
Financial 
consolidation 
challenges
Calculation engine consolidates revenue, COGS, and margins 
from dealers and plants to HQ in real time.
Manufacturing 
inefficiency
Production KPIs feed into FireFlight; scenario engine reallocates 
production to high-performing plants.
Maintenance parts 
inventory tracking
Real-time inventory updates ensure spare parts are available 
when needed across all locations.

Event Flow Example

A dealer sells a forklift → FireFlight captures the sale event

Inventory at regional warehouse and plant updated automatically

Stockout risk triggers transfer optimizer to suggest shipment from nearest plant or warehouse

Dealer or warehouse manager approves transfer

 Transfer cost logged; inventory marked in transit

Scenario engine simulates production adjustments and shipping strategies for upcoming demand

 Financial dashboards automatically update P&L at dealer, plant, regional, and HQ levels

Data & Technical Highlights

Canonical entities: Product Model, Lot/Batch, Plant, Dealer, TransferOrder, Sale, ProductionRun, MaintenancePar, FreightInvoice, JournalEntry

Event bus: append-onlytransactional event stream for all sales, production, and inventory events

 Materialized views: fast roll-ups for dealer/plant financials, inventory metrics, and KPIs

Calculation layer: versioned business rules for cost, margin, and oll-ups

 APIs/connectors: Plant MES, Dealer POS, WMS, ERP integration

Security: role-based access, row-level controls, full audit logging

KPIs Monitored

 Dealer: forklift stockouts, maintenance parts availability, gross margin, lead times

Plant: units produced, yield %, scrap, changeover time, cost/unit, machine utilization

 Region: transfer cost/unit, fill rates, inventory carryingcost, delivery performance

HQ:consolidated revenue, COGS, margin, cash tied to inventory, operational efficiency metrics

Implementation Phases

Phase 1 (30–60 days):FireFlight environment setup, pilot plants and dealers connected, inventory and financial calculation engines deployed

Phase 2 (2–3 months):Transfer optimizer, dealer dashboards, workflow approvals, historical data migration, KPI tracking

Phase 3:Full MES integration, scenario engine for production optimization, CI/CD for rule changes, full roll-ups and auditing at HQ, continuous performance monitoring

Outcome

FireFlight transformed Ighama Tractor and Forklifts from a reactive, disconnected 
organization into a proactive, data-driven company:

Optimized forklift and spare parts movement across plants and dealers, reducing stockouts and overstock

Significantly reduced shipping and emergency delivery costs

 Provided accurate, auditable financial consolidation from dealers to HQ

Improved manufacturing efficiency through data-driven decisions and reallocation of production

 Delivered full visibility and actionable insights across dealers, wrehouses, plants, and HQ

Ighama now operates efficiently at a national scale, makes informed strategic decisions, reduces costs, and ensures high availability of products and parts for their customers.

The names of this company has been changed to protect their information, and each scenario represents a practical use case of FireFlight.