How SAR Auto Products Ltd. Improved Operational Efficiency with SETU’s ERP Implementation
Client Background
Our client is a prominent manufacturer of high-precision automotive components. With over two decades of industry experience, they specialize in the production of synchronizer rings, cones, sleeves, hubs, gears, gearboxes, and power transmission parts for differential and engine gearboxes. The client operates an advanced manufacturing setup equipped with CNC and VMC machines.
Problem Statement
Prior to the ERP implementation, the client faced several operational challenges
due to fragmented systems and manual processes, such as:
The need was clear for a robust and integrated ERP system to streamline operations, ensure compliance, and enhance productivity across departments.
All operations were managed using Excel and paper-based documentation.
Difficulty in tracking material inward and consumption
Lack of visibility into production scheduling and subcontractor management
Disjointed quality and maintenance tracking, leading to frequent downtime
Inaccurate and inconsistent record-keeping across departments.
Difficulty in tracking production performance, material usage, and maintenance schedules
Implementation
We Implemented Odoo ERP tailored to the client's unique operational needs.
The implementation followed a phased approach including:
Requirement analysis and process mapping
Custom workflow configurations for approvals and quality checks
Data migration from legacy systems
User training and handholding
Post go-live support and AMC
Modules implemented
Sales
Purchase
Inventory
Manufacturing
Quality
Maintenance
Approvals
Reporting
Dashboards
Operations Implemented
Sales Management
Seamlessly create, send, and manage quotations with automated follow-ups.
Advanced price list and discount configuration.
Support for multiple units of measure (UOM).
Automated E-Way Bill and E-Invoice generation.
Manage party-wise HSN codes and auto-fill them in E-Way Bills.
Set and transmit automatic distance parameters within E-Way Bill requests.
Purchase Management
Centralized supplier and vendor management.
Vendor-specific RFQ (Request for Quotation) generation.
View historical purchase rates from the last three orders.
Dynamic rate management based on raw material (Base & Steel) pricing.
Comprehensive inward material tracking.
Integrated Gate Pass and Gate Entry system for goods movement.
Inventory Management
Manage multiple warehouses and locations efficiently.
Real-time stock movement and transfer tracking.
Internal transfer functionality between locations and warehouses.
Automated reordering using minimum stock rules.
Complete lot and serial number traceability for robust stock control.
Approval Workflow
Configurable conditional approval processes for purchase orders.
Special approval flow for purchases involving major price deviations.
Manufacturing Management
Auto-generation of Bills of Materials (BoM).
Configurable work center operations and activity tracking.
Comprehensive subcontracting and job work management.
Detailed production order scheduling and execution tracking.
Machine-wise production control for increased efficiency.
Job Work & E-Waybill Integration
Job Work Challan generation.
Track goods sent out for job work with WIP (Work in Progress) management.
Automatically highlight price changes for standardized job orders.
E-Way Bill generation for job work considering material cost.
Quality Control
Define and manage quality control points across production.
Log unit-wise reasons for product rejections and rework with clarity.
Rework Process Management
Assign unique codes for deviated products.
Automate scrap location management for rejected materials.
Maintenance Management
Create, track, and resolve maintenance requests efficiently.
Plan and automate preventive maintenance schedules.
Enable approval flow for maintenance requests.
Monitor machine downtime trends to address recurring issues.
Analyze machine performance using operational vs. downtime hours.
Track specific breakdown reasons and maintenance costs accurately.
Dashboard & Advanced Reporting
Reports
Pending Purchase Orders
Purchase Orders Pending Approval
Open Orders & Material Receipt Status
Rejection and Rework Reports
Pending PO Material Summary (Partial/Full Receipts)
Costing Open PO List (Costing Yet to Be Added)
ITC-4 Compliance Report
Goods Receipt Note (GRN)
Returnable Gate Pass
Job Work Challan
Tax Invoice & Proforma Invoice
Dashboard
Visual summary of Pending, Approved, and Open Purchase Orders
Real-time data visibility for decision-makers
Conclusion
The Odoo ERP implementation transformed the client’s business by digitizing and integrating their core operations. With improved transparency, operational efficiency,
and compliance readiness, the client now benefits from:
80% improvement in production visibility and planning
Enhanced quality and maintenance control
Accurate reporting and real-time dashboards for faster decision-making
The system continues to evolve with the client’s growth, supported by our ongoing AMC services.
