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Case study · Manufacturing · Platforms & portals

From wage spreadsheet to one tested engine

Factory wages for an international manufacturer used to run on a large, complicated spreadsheet system. We replaced it with a platform that captures clock-ins automatically, builds shifts, flags exceptions every morning, and delivers each factory's wage pack every Monday at 08:00.

  • Since 2025
  • 16 days

    From the first line of code to the first wage report, and live within a month

  • 1,500+

    Clock events a day at a single factory, paired into shifts automatically

  • Mon 08:00

    Wage packs in each factory's inbox, with no manual build

  • 2 countries

    Factories in two countries, each in its own time zone, on one platform

At a glance

Client
International security manufacturer
Users
Factory managers, wage administrators, HR, approvers, and finance
Delivery
First wage report in 16 days; in production within a month (2025)
Platforms
Management portal and an iOS, Android, and web clocking app
Integrations
Factory access-control door scanners, Active Directory, cloud file storage
Footprint
Factories in two countries, each in its own time zone

01The situation

Our client runs factories staffed partly by their own employees and partly by workers from third-party labour providers, each with its own rate card. Every week, thousands of clock-ins had to become an accurate wage bill.

That job lived in a large, complicated spreadsheet system: hard to change, hard to check, and dependent on the few people who understood how it worked.

  1. 01

    A spreadsheet nobody wanted to touch

    Pay rules, rates, and exceptions were buried in formulas, so every change risked a silent error in someone's pay.

  2. 02

    Raw clock data, manual clean-up

    Scanner data has missing punches, night shifts that cross midnight, and duplicate scans, all of which had to be found and fixed by hand.

  3. 03

    No forecast, no audit trail

    There was no easy way to compare actual wage cost against forecast, or to see who changed a figure and why.

02What changes

  • Pay rulesThe spreadsheet: Buried in spreadsheet formulas.The wage system: Codified once in a tested wage engine that every report shares.
  • Clock dataThe spreadsheet: Missing punches and overnight shifts sorted out by hand.The wage system: Door scans synced every 5 minutes and paired into shifts automatically.
  • ExceptionsThe spreadsheet: Spotted, or missed, while building the sheet.The wage system: Shifts outside normal hours emailed to each factory every morning; 10 attendance rules on a live dashboard.
  • CorrectionsThe spreadsheet: Changed in the sheet, with no approval step.The wage system: Submitted with a comment and approved exactly as submitted, with before and after kept.
  • Weekly wagesThe spreadsheet: A manual build every week.The wage system: Wage and shift workbooks emailed to each factory every Monday at 08:00.
  • Cost controlThe spreadsheet: Forecast versus actual worked out by hand.The wage system: Forecast versus actual by process and labour provider, with tolerance alerts.

03How it works

A pay week, end to end

  1. 1

    Clock

    Door scanners and the manager app capture every clock-in. App clocks carry a photo and GPS position as evidence.

  2. 2

    Build shifts

    Every hour, clock events are paired into day and night shifts, missing punches are inferred and flagged, and each shift is checked against the worker's schedule.

  3. 3

    Flag

    After 08:00 each morning, shifts that ran outside normal hours are emailed to the factory for correction; Monday's email covers Friday to Sunday. Ten attendance rules run on the exceptions dashboard.

  4. 4

    Correct & approve

    Admins fix the clock data with a comment for the reviewer. The approver approves exactly what was submitted, or rejects it with a reason.

  5. 5

    Calculate

    The wage engine applies hours, overtime, Sunday and night rates, labour-provider rate cards, production bonuses, and levies.

  6. 6

    Deliver

    On Monday at 08:00, every factory receives its wage and shift workbooks, while finance tracks cost against forecast all week.

04What we built

  • Automatic clocking

    Door scans sync from the factory access-control system every five minutes. Managers can also clock workers in and out from a phone, with a photo as evidence.

  • One wage engine

    Normal hours, overtime and Sunday rates, night allowances, labour-provider rate cards, capacity-capped production bonuses, and levies, in one engine behind every report and dashboard.

  • Exceptions approved, not edited

    A daily check for out-of-hours shifts, plus a dashboard of ten attendance rules with severity levels and wage-tolerance checks. Corrections are approved exactly as submitted, with a full history of who changed what and why.

  • Seven dashboards

    Wage cost and hours by day, including staff still on shift, attendance and reliability, production, two exception views, and a door-scanner-versus-app comparison.

  • Still Excel where it helps

    The weekly wage workbook opens in Excel with live formulas and optional hour caps, and an automated test proves those formulas match the engine.

  • People, sick leave & production

    Staff records with permits, concerns, and terminations, a sick-leave register that tracks missing notes and days lost, and daily production logs per machine.

05What each team gets

  • Factory managers

    • Clock staff in and out from a phone, with photo evidence
    • See attendance and reliability for their factory
    • Log daily production per machine
  • Wage administrators

    • Exceptions listed and emailed, not hunted for
    • Corrections with a clear approval trail
    • The weekly workbook, still in Excel, built for them
  • HR

    • Staff records, permits, concerns, and terminations in one place
    • A sick-leave register with missing notes and days lost
    • A daily exchange report of starts, exits, and workforce events, on demand
  • Finance & management

    • Wage cost and hours dashboards, day by day
    • Forecast versus actual by process and labour provider
    • Pay figures hidden from anyone without permission

06How we delivered

  1. Month 1

    Live in production

    The first wage report 16 days after the first line of code, and into production within the month.

  2. Mid 2025

    Mobile clocking

    An iOS and Android clocking app with photo evidence for every manual clock-in.

  3. 2026

    Scale out

    A second-country instance, multi-factory time zones, labour-provider rate cards, production bonuses, forecasting, and sick leave.

  4. Aug–Oct 2026

    One tested engine

    Wage rules consolidated into a single tested engine, then daily exception approvals and formula-driven wage workbooks.

07Built to last

  • A pure-function wage engine shared by every report, forecast, and dashboard, with its own automated test suite.
  • Excel formulas tested against the engine, so the workbook and the system can't quietly drift apart.
  • Approvals that are safe under load: serializable transactions, version checks, and unique run keys mean no double approvals and no duplicate emails.
  • Reliable scanner sync that catches late-arriving scans without creating duplicates.
  • Every door scanner monitored: one that goes quiet at a time it's normally busy is flagged.
  • Encrypted identity and tax numbers, and a permission that hides every monetary value.
  • .NET
  • ASP.NET Core
  • SQL Server
  • Angular
  • Capacitor
  • Active Directory
  • GitHub Actions

Still running payroll or operations on a spreadsheet nobody wants to touch?

We'll map the rules in your spreadsheet and show you what a tested, automated system could look like. Book a free 30-minute call with one of our engineers.

sales@happen.software · www.happen.software/contact

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