Client Overview
A prominent manufacturer of high-pressure hose assemblies and fittings, strategically headquartered in the Adityapur Industrial Area of Jamshedpur, Jharkhand. The company serves prestigious clients such as Tata Steel Pvt. Ltd. and Thriveni Earthmovers Pvt. Ltd., delivering a wide range of rubber hose assemblies, steel tube assemblies, and fluid connectors across India and globally.
Operating from three primary manufacturing units in Jamshedpur, Hazaribagh, and Jajpur, and supported by depots in Noamundi, Ghatotand, and Joda for assembly operations, Hydrokrimp maintains a strong distribution and service footprint.
Business Challenges
Despite their operational scale and expertise, Hydrokrimp faced several key challenges that impacted cost visibility, efficiency, and data management:
- Inaccurate Finished Goods Costing
Due to fragmented processes and lack of real-time data across work centers, calculating actual production costs involved manual efforts, consuming hours or even days with uncertain accuracy. - Complex BOM Management
Multiple Bills of Materials (BOMs) for the same finished goods across different locations made inventory reconciliation and stock accounting cumbersome. - Growing Master Data Issues
As the product line expanded, duplication and integrity issues surfaced in master data, making data retrieval inefficient and error-prone. - Inefficient Warehouse Mapping
Without product-to-bin mapping in the warehouse, there was limited stock visibility, poor traceability, and inefficient replenishment—leading to overstocking or stockouts. - Untracked Scrap Generation
The absence of real-time scrap tracking during production led to discrepancies in inventory levels and miscalculated production costs. - Cumbersome Estimation Process
Make-to-order estimation was complicated by multi-supplier component sourcing, resulting in slow responses and revenue leakage.
Implemented Solution
To address these bottlenecks, a cloud-based ERP platform was implemented, featuring an integrated Manufacturing, Warehouse, and Estimation module tailored to Hydrokrimp’s operations.
Key Features & Capabilities:
- Accurate Finished Goods Costing
Advanced features such as Routing, Task Tracking, and detailed Operation Reporting allowed real-time, precise calculation of finished goods costs—improving budget accuracy and strategic planning. - Centralized Master Data Management
A single source of truth for materials, products, and processes eliminated duplication, improved data consistency, and enhanced search and retrieval functionality. - Flexible BOM Handling
The ability to manage different BOMs for the same product across locations simplified operations and reduced reconciliation effort. - Enhanced Warehouse Management
Real-time bin and location mapping improved picking efficiency, replenishment workflows, and traceability of inventory. - Real-Time Scrap Reporting
Scrap could now be recorded during production at the source, allowing for accurate finished goods costing and inventory adjustments. - Customized Estimation Module
The system now offers faster, more accurate estimations for make-to-order products, leading to quicker response times and improved sales conversions. - Integrated Quality Control
Embedded quality checks help maintain consistent product standards and reduce rework or wastage.
Business Impact
- Time Savings: Manual cost calculations were eliminated, reducing hours of work to near-instant analytics.
- Improved Accuracy: Real-time tracking ensured that cost figures were reliable and actionable.
- Greater Operational Visibility: Teams across manufacturing, sales, and inventory gained clarity with centralized data and dashboards.
- Faster Customer Response: Accurate and timely quotations improved customer satisfaction and reduced revenue leakage.
- Inventory Optimization: Real-time stock visibility helped avoid both stockouts and excess inventory.
Conclusion
By implementing an integrated ERP tailored to their unique production and warehousing environment, The company transformed their operational efficiency, cost accuracy, and decision-making capabilities. The solution brought measurable improvements in productivity, customer responsiveness, and data reliability—empowering the company for future growth.