Caplugs
Serving clients in industries from medical to mining.
Delivered a 20-page cloud and security readiness assessment in one week, built with Claude’s Sonnet 4.6 model and CodeQuill.ai (a proprietary AI Documentation tool), so a global manufacturer could sequence its modernization work before setting a deployment date.
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Caplugs (Protective Industries), a manufacturer of protective components, was preparing a new international deployment and needed to know whether an existing manufacturing execution system could come along. The application was a .NET WinForms MES with years of accumulated logic behind it, and the company needed it assessed for integration with its modern cloud ERP environment before committing to a go-live date. First Factory applied a disciplined engineering approach, leveraging Claude Code and the Claude SDK to analyze the full codebase, a ~16,500-line core data-access class and ~200 UI forms, and the Claude API to structure a technical and security assessment. The goal was to quickly and accurately evaluate integration feasibility, cloud readiness, and applicable data-protection considerations. Three strategic questions framed the work: migration to Business Central, deployment on Azure, and security and PDPA compliance.
Caplugs was preparing a manufacturing international deployment and needed to know whether its existing manufacturing execution system could integrate with Business Central, run on Azure, and satisfy the country's PDPA requirements. The answers lived in the code: a 16,500-line core data-access class and roughly 200 WinForms screens built up over years of production use. A manual review at that depth runs about 120 engineering hours, and Caplugs needed an answer before it could commit to a date. We ran the codebase through CodeQuill.ai, our proprietary assessment tool built on the Claude API using Anthropic’s Sonnet 4.6 model, and delivered a 20-page readiness assessment in one week. Actual engineering time was 20 hours including senior validation of every finding, a 77% reduction in cost against the manual baseline.
The assessment answered all three questions and produced a remediation roadmap prioritized across immediate, 30 to 60 day, and 60 to 120 day windows, plus a phased Business Central migration strategy. Caplugs sequenced its modernization work from evidence in its own codebase rather than estimates. The engagement has since grown into ongoing staff augmentation across e-commerce and internal ERP workstreams, where the team maintains a structured knowledge base of the platform's architecture and business logic that both engineers and Claude query as a shared source of truth.
Founded in 1948, Caplugs is a global leader in component protection, specializing in injection molding, vinyl-dip molding, and extrusion to produce premium plastic caps, plugs, fasteners, and netting. The company is committed to operational excellence and speed, maintaining a vast, ready-to-ship inventory of over 400 million parts covering more than 14,000 different catalog items. Their comprehensive product line provides critical protection across diverse industries, from automotive and hydraulics to highly regulated sectors like medical and aerospace, ensuring components are shielded from damage and contamination during manufacturing, shipping, and storage.
