From three notebooks and a spreadsheet to one shop-floor system

Production was planned on a whiteboard, issues to the shop floor were written in notebooks, and finished goods were reconciled once a month against a spreadsheet maintained by one person.

Nobody could answer what raw material was on hand without walking to the stores. Month-end close took the accounts team six working days.

Two weeks of discovery on the floor, sitting with the stores in-charge, the production supervisor and the accountant.

ERPNext configured for Accounts, Stock, Buying, Selling and Manufacturing with bills of material for the twelve highest-volume parts.

Item masters rebuilt from scratch with a naming scheme the supervisor helped write. Three years of transactions and verified opening balances migrated.

Simplified entry screens for the shop floor: four fields on a material issue instead of nineteen. Training in Marathi, at their own machines, over three weeks.

Stock valuation is now available on demand rather than at month end, and close runs in a single evening.

The parallel spreadsheet was retired in the second month after go-live and has not come back.

Purchase decisions now start from the reorder report instead of a phone call to stores.