₹12 Lakh Annual Savings + 99.2% Inventory Accuracy
Custom ERP for a Gujarat Manufacturer
How a mid-size manufacturer unified 3 facilities and saved ₹12L annually with custom ERP.
System architecture
Modules and integrations delivered for this engagement.
Project Value
₹30L–₹50L
Timeline
14 weeks
Industry
Manufacturing
Team Size
6 engineers
Business Outcome
Cost Reduction
Support Period
12 months
Overview
Executive Summary
A precision manufacturing group operated three production facilities with disconnected Excel workflows, manual inventory counts, and two-week month-end reconciliation cycles. Maxwell Electrodeal designed and deployed a modular ERP aligned to their GRN → production → QC → dispatch workflow. Within 14 weeks, all facilities were live with barcode scanning, real-time dashboards, and Tally integration—delivering measurable ROI in the first quarter.
Client Profile
Leading manufacturing organization
Mid-size precision manufacturing company producing 200+ SKUs for automotive and industrial clients across Gujarat.
- Size
- 450 employees · 3 facilities
- Sector
- Precision Manufacturing
Initial Situation
Where they started
Operations ran on Excel spreadsheets and legacy Tally disconnected from the shop floor. Production scheduling happened via WhatsApp. Inventory accuracy sat at 87%, causing material shortages and delayed orders worth ₹15L+ annually in waste.
Before
- Excel-based inventory across 3 sites
- WhatsApp production scheduling
- 2-week month-end reconciliation
- 87% inventory accuracy
After
- Real-time unified ERP dashboard
- Automated production scheduling
- Same-day financial reconciliation
- 99.2% inventory accuracy
Strategy
Challenges & Project Goals
What blocked progress before delivery — and what leadership signed off to achieve.
Key challenges
- No real-time visibility across 3 warehouses and production lines
- Manual data entry causing errors and 2-week reconciliation cycles
- Production scheduling via informal channels with no capacity planning
- Supplier coordination through phone calls and email with no portal
- Finance team unable to reconcile shop floor data with accounting
Project goals
- Unify inventory, production, and finance across all facilities
- Reduce manual data entry by at least 35%
- Achieve 95%+ inventory accuracy with barcode scanning
- Enable real-time OEE dashboards for plant managers
- Integrate with existing Tally for GST-compliant accounting
Discovery & Planning
How we planned the engagement
- 12-week shop floor observation across all 3 facilities
- 2Workflow mapping workshops with production, inventory, and finance teams
- 3Current-state process documentation and pain point prioritization
- 4Phased rollout plan: Facility 1 pilot → validation → Facilities 2 & 3
- 5Technical architecture review with IT and Tally integration partner
Solution Architecture
Technology architecture
Modular microservices architecture with a React admin portal, shop floor tablet apps, PostgreSQL for transactional data, and AWS for hosting. Tally sync runs as a dedicated integration service with bi-directional GST-compliant data flow.
Process
End-to-end workflow
GRN Receipt
Barcode scan on material arrival
Production
Work order execution with BOM tracking
Quality Check
Digital QC checklist with photo capture
Dispatch
Automated invoicing and Tally sync
UI/UX design process
- 1Role-based dashboard wireframes for management, supervisors, and operators
- 2Shop floor UX optimized for gloved hands and tablet use in factory lighting
- 3Interactive prototypes tested with 12 end users before development
- 4Visual hierarchy designed for at-a-glance OEE and inventory status
Development process
- 1Agile sprints with weekly demos to plant managers
- 2Barcode integration for inventory scanning on shop floor tablets
- 3Real-time PostgreSQL with read replicas for reporting performance
- 4Tally bi-directional sync for GST-compliant accounting
- 5Phased rollout: Facility 1 → 2 → 3 over 8 weeks post-MVP
Technical
Technology stack & deployment
Technology stack
Deployment strategy
- Pilot deployment at Facility 1 with parallel run for 2 weeks
- Staff training program: 3 sessions per role before go-live
- Blue-green deployment for zero-downtime updates
- 24/7 monitoring with escalation to Maxwell support team
- Post-launch hypercare for 30 days with on-site support
Timeline
Project timeline
Phased delivery from discovery through rollout and hypercare.
Discovery
3 weeksShop floor observation, workflow mapping, requirements
Design
2 weeksWireframes, prototypes, user validation
Development
7 weeksCore modules, Tally sync, barcode integration
Rollout
2 weeksPhased deployment across 3 facilities
Key milestones
Discovery Complete
Workflow maps signed off by COO
MVP Live
Facility 1 production go-live
Full Rollout
All 3 facilities operational
ROI Validated
₹3L quarterly savings confirmed
ROI
Results & ROI
Measurable business impact delivered within the agreed timeline.
Production scheduling and dispatch
Automated shop floor data capture
Waste and overtime reduction
Since full rollout
Automated data capture from shop floor
Reduced waste and overtime costs
Up from 87% with manual counts
Discovery to all-facility rollout
Engagement summary
Delivery at a glance
Documented delivery parameters for a Leading manufacturing organization — documented in case study review.
Challenge
No real-time visibility across 3 warehouses and production lines
- Manual data entry causing errors and 2-week reconciliation cycles
- Production scheduling via informal channels with no capacity planning
Solution
Modular microservices architecture with a React admin portal, shop floor tablet apps, PostgreSQL for transactional data, and AWS for hosting. Tally sync runs as a dedicated integration service with bi-directional GST-compliant data flow.
Business outcome
40% Less Manual Entry
Automated data capture from shop floor
Timeline
14 weeks
Support: 12 months
Team size
6 engineers
Technology stack
ROI indicator
45% — Faster Operations
Production scheduling and dispatch
Client feedback
“Maxwell understood our factory floor better than the big ERP vendors. The system works the way we work—not the other way around. ROI was visible within the first quarter.”
ROI highlight
45%
Faster Operations
Production scheduling and dispatch
- Timeline
- 14 weeks
- Team
- 6 engineers
Insights
Lessons learned
- Shop floor observation before wireframes prevents costly rework
- Phased rollout beats big-bang deployment for manufacturing adoption
- Tally integration must be scoped early—not treated as an afterthought
- Operator training is as critical as the software itself
Key results
40% Less Manual Entry
Automated data capture from shop floor
₹12L Annual Savings
Reduced waste and overtime costs
99.2% Inventory Accuracy
Up from 87% with manual counts
14 weeks Full Delivery
Discovery to all-facility rollout
ROI: 45% Faster Operations — Production scheduling and dispatch
Implementation approach
How delivery was structured
Existing process
Operations ran on Excel spreadsheets and legacy Tally disconnected from the shop floor. Production scheduling happened via WhatsApp. Inventory accuracy sat at 87%, causing material shortages and delayed orders worth ₹15L+ annually in waste.
Pain points
- No real-time visibility across 3 warehouses and production lines
- Manual data entry causing errors and 2-week reconciliation cycles
- Production scheduling via informal channels with no capacity planning
- Supplier coordination through phone calls and email with no portal
Solution
Modular microservices architecture with a React admin portal, shop floor tablet apps, PostgreSQL for transactional data, and AWS for hosting. Tally sync runs as a dedicated integration service with bi-directional GST-compliant data flow.
Timeline
14 weeks
Technology stack
React · Node.js · PostgreSQL · AWS · TypeScript · Redis
Strategic insights
Lessons for similar operators
- →Shop floor observation before wireframes prevents costly rework
- →Phased rollout beats big-bang deployment for manufacturing adoption
- →Tally integration must be scoped early—not treated as an afterthought
- →Operator training is as critical as the software itself
“For manufacturing engagements like this, executive sponsorship and phased go-live matter as much as architecture — 14 weeks only works when change management keeps pace.”
Evidence-backed data
Statistics & benchmarks
Sourced from Maxwell research, reports, and documented client engagements — with publication dates.
Industry statistics
22%
Majority still rely on spreadsheets, Tally-only setups, or fragmented tools.
Source (2024-06-01): IDC India SMB Survey 2024
#1
Specialty chemical manufacturers in GIDC clusters.
Source (2026-03-01): Maxwell Electrodeal — Digital Transformation in Chemical Industry Report
Market trends
30%
Manufacturing teams re-keying dispatch, GRN, and production data into spreadsheets.
Source (2023-09-01): Deloitte India Operations Report 2023
$2.5B
Projected market size driven by SME digitization and GST compliance pressure.
Source (2024-11-01): NASSCOM 2024 SMB Tech Report
Benchmarks
8–12 mo
Mid-market manufacturers with custom ERP and Tally integration.
Source (2023-09-01): Deloitte India Operations Report 2023
6–9 mo
Barcode + ERP sync engagements in manufacturing SMEs.
Source (2026-01-15): Maxwell Electrodeal — Inventory Automation Case Study
Case study FAQs
- What was the main challenge for this manufacturing engagement?
- No real-time visibility across 3 warehouses and production lines
- What was the implementation timeline?
- 14 weeks — Discovery (3 weeks); Design (2 weeks); Development (7 weeks); Rollout (2 weeks).
- What ROI or business outcomes were achieved?
- 40% Less Manual Entry — Automated data capture from shop floor
- What technology stack was used?
- React, Node.js, PostgreSQL, AWS, TypeScript, Redis
Related resources
Resources & guides
Services
Industries
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