Client Overview
A recognized ISO-certified manufacturer of diesel generator (DG) sets in the 5 KVA to 500 KVA range operates around Mahindra powertrains. Known for its manufacturing excellence and a national dealer footprint, the organization is also expanding into switchgear, control panels, and special-purpose gensets.
While enclosures are manufactured in-house, the company sources nearly all critical components. Products are expected to maintain 100% reliability in varied global operating conditions. The organization also manages After-Sales Service, AMC contracts, warranty administration, and ensures spare parts availability across markets.
Business Challenges
With growing product complexity and a nationwide customer base, several key operational pain points were identified:
- Complex Operations
A wide product and component range made procurement, production planning, and material requirements planning (MRP) difficult to manage manually. - Lack of System Integration
Core processes like production scheduling, inventory tracking, and financial management were handled using spreadsheets and a standalone desktop accounting system—resulting in data silos and operational delays. - ISO Compliance
The company needed a system that could enforce standard operating procedures and maintain audit-ready documentation in line with ISO and other regulatory standards. - Customer-Centric Operations
With a growing service network, it became essential to improve visibility into customer expectations, service history, and support fulfillment to build better relationships and ensure parts availability.
Strategic Objectives
- Improve production efficiency and planning accuracy
- Enable cost savings and better cost control
- Ensure quality compliance with ISO standards
- Provide real-time insights across procurement, inventory, manufacturing, and service
- Scale operations to support nationwide dealers and service partners
The ERP-Led Transformation
A comprehensive ERP system was deployed, tailored to manage manufacturing, service, procurement, sales, and finance—all integrated under one platform.
Core Modules Implemented
Manufacturing Management
- Bill of Materials (BoM): Engineering and Sales BoM flexibility
- Work center Routing
- Production Orders and Simulations
- Real-time Production Costing
- Stage-wise production workflows
Procurement Management
- Purchase Requisition and Order Workflow
- RFQ & Supplier Quote Management
- Special Item Procurement
- Purchase Returns Handling
Inventory Management
- Real-time Inventory Operations
- Automated Component Replenishment
- GST-Compliant Stock Transfers
Sales & Customer Service
- Quote-to-Order Management
- Sales Returns and Dispatch
- Subcontracting Order Tracking
Financial Management
- General Ledger and Sub-ledgers
- Accounts Payable and Receivable
- Fixed Assets Management
- Multi-dimensional Financial Reporting
Solution Benefits
- Streamlined operations across departments
- Improved production planning with granular cost tracking
- Reduced waste and operational cost
- Standards compliance for audits and ISO requirements
- Enhanced service fulfillment across the country
- Component availability and inventory optimization
Conclusion
By replacing disconnected legacy systems with a robust, integrated ERP platform, the organization was able to digitally transform its manufacturing, sales, and service processes. This ensured agility, transparency, and compliance—positioning the company for scalable growth in both domestic and international markets.