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
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.