Custom ERP for a Gujarat Manufacturer
Unified ERP across 3 production facilities with real-time inventory and supplier integration.
Client
Leading manufacturing organization
A mid-size precision manufacturing company operating 3 production facilities across Gujarat, producing 200+ SKUs for automotive and industrial clients.
Duration
14 weeks
Team
6 engineers
Industry
Manufacturing
Challenge
The business problem
Operations ran on Excel spreadsheets and a legacy Tally setup disconnected from the shop floor. Inventory counts across 3 facilities were manual, production scheduling happened via WhatsApp, and month-end reconciliation took 2 weeks. Errors caused material shortages, delayed orders, and ₹15L+ in annual waste.
Strategy
Our approach
We designed a modular ERP around their actual workflow—GRN → production → QC → dispatch—rather than forcing SAP-style processes. Phase 1 delivered inventory and production modules. Phase 2 added finance integration with Tally and a supplier portal.
Design process
- 1Shop floor observation across all 3 facilities for 2 weeks
- 2Workflow mapping sessions with production, inventory, and finance teams
- 3Role-based dashboard wireframes for management, supervisors, and operators
- 4Interactive prototypes tested with 12 end users before development
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
- 4Tally bi-directional sync for GST-compliant accounting
- 5Phased rollout: Facility 1 → 2 → 3 over 8 weeks
Technology stack
Key features delivered
- Multi-warehouse inventory with barcode scanning
- Work order management and BOM tracking
- Production scheduling with capacity planning
- Quality control checklists with photo capture
- Supplier portal for PO and ASN management
- Real-time OEE dashboards per production line
Project screenshots
Client screens shown under NDA. Request a full demo walkthrough →
- erp
Production Dashboard
Available on consultation
- dashboard
OEE Analytics
Available on consultation
- mobile
Shop Floor App
Available on consultation
Impact
Results & business impact
Automated data capture from shop floor
Reduced waste and overtime costs
From 87% with manual counts
From discovery to full rollout
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.”
Project snapshot
40% reduction in manual data entry
Primary outcome
- Industry
- Manufacturing
- Duration
- 14 weeks
- Team
- 6 engineers
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