Streamlining End-to-End Electrical Cable & Wire Manufacturing through Odoo

Today, we will go through the success story of our electrical cable & wire manufacturing client where in we have streamlined their end to end manufacturing using Odoo.

The client is from the electrical cable & wire manufacturing industry and he has a mid sized plant with around 200 employees in Sahibabad, Uttar Pradesh, India.

The company is mostly into making electrical cables and wires for use in homes, offices, and factories. On a day to day basis they usually buy raw materials for the manufacturing which includes components like copper, aluminium, and insulation materials. They are supplying their manufactured product to local and international markets.

The client is one of the trusted suppliers in North India due to the fact that they are known for on time delivery and maintaining a good quality of their production.

Let’s Check their on Ground Challenges

When we visited their electrical cable & wire manufacturing plant we saw that they were using separate systems to manage their purchase, inventory, production, be it quality checks and their machine maintenance departments and this was causing them delays and lot of confusions.

A Run Down on their Pain Points

They were not able to keep a track of the raw materials they were procuring and the finished goods produced at the location leading to problem that they had no clear view of their inventory and production stages. Apart from that, their quality checks were inconsistent and whenever any of their machines broke down unexpectedly it directly slowed down their production.

What was the impact?

So, after we completed our visit at their electrical cable & wire manufacturing plant, impacts were recorded by us where in we saw that shortage of stock or having excess inventory at hand was leading to incurring extra costs, customer trust was being hurt due to late order deliveries, sometimes there were defects in products which led to waste accrual. Apart from that, the machinery repairs and downtime was also something that was increasing their cost.

Client Goals & Expectations

The client was straight forward they said that they wanted to see their inventory and production in real time, reduce defects and machine downtime within the plant, a simpler way to make purchase and maintenance, and foremost they wanted to improve their overall manufacturing efficiency.

The client was expecting that all of their departments should be working together in one system, managers and workers should have their own separate dashboards, and most importantly there should be automatic alerts and notifications for important tasks.

They were looking to measure success in terms of like – reduction of raw material wastage by 20%, improving their production efficiency by 15% and cutting downtime of machines by 25%.

Scope of Work for their Electrical Cable & Wire Manufacturing

Below are the departments that we have covered using Odoo modules:

• Purchase
• Inventory
• Manufacturing
• Quality Control
• Maintenance

We have automated various processes including –

• Purchase to production planning
• Stock tracking and movement
• Quality checks on batches
• Preventive maintenance scheduling

There were few complexities that we had to handle at our end like –

• The client had multiple sites but and we had to manage everything using one unified system.
• We also had to work on compliance part keeping in mind the safety and quality standards.
• Apart from that, we had to make some customizations as per their cable production workflows.

Proposed Solution Implementation

We utilized Odoo ERP solution and used modules – Odoo Purchase, Inventory, Manufacturing, Quality, and Maintenance. Apart from that we also proposed some customization work that included – automatic reordering of raw materials, batch tracking for production and quality checks, along with scheduled preventive maintenance for their machines.

They also were requiring some automation and integrations which included work on – production, inventory, and quality check data connected in real time along with alerts for low stock and upcoming maintenance.

What Challenges Were There During Implementation

The client’s staff was basically used to manual processes and we needed to move their data from spreadsheets and old system to the new proposed system. We also saw them checking their copper coils stock using paper registers where it was a mismatch with the actual availability.

To help their staff we provided them with hand on training sessions, we rolled out the system in phases to avoid any confusions, and provided simple dashboards as per requirements to individuals.

What Changed When Odoo Was Introduced

Well there was a significant operational boost for the client’s manufacturing processes. Now they have gauged 20% less raw material wastage, 15% more efficient production, 25% lesser downtime of the machinery, and faster order fulfillments.

Their operations have also improved where they can now see that the purchase to production workflows have smoothened out, they have better quality control along with batch tracking and preventive maintenance has stopped unexpected breakdowns of their machines.

Apart from that they now have the leverage of long term benefits that include – real time data for making better decisions, standardized process across all departments, and they are already ready for their future growth.

Client Feedback

“Odoo ERP has changed the way we work. From buying raw materials to machine maintenance, everything is now simple and clear.”
— Plant Manager, Sahibabad Cable Manufacturing Plant

Key Innovations

We have introduced a single unified system that has everything under single umbrella and it connects purchase, inventory, production, quality, and maintenance departments. They have batch tracking that helps them in better quality management, they can use the scheduled maintenance for their machines to prevent breakdowns, and managers get dashboards to monitor everything that is going on within operations.

lastly, i would say that now the client’s plant is running smooth and they have cut costs and improved their efficiency and achieved what they had in mind using the Odoo ERP solution.

To know more drop us a line at sales@apagen.com or call us on +91 9971800665.