Client Overview
A legacy brand with over 70 years of excellence in redefining comfortable sleep for Indian consumers, the client is one of the country’s largest manufacturers of latex foam rubber mattresses. Headquartered in Bangalore with a manufacturing unit in Chennai, the company has a strong footprint across metro and non-metro regions.
Their product line includes mattresses, pillows, cushions, bolsters, aircraft and luxury bus seating, and upholstery sheeting—designed to meet the needs of modern lifestyles with premium comfort.
Business Challenges
Despite its market leadership and decades of experience, the company faced growing operational complexities. It became evident that to stay competitive, they required a robust digital transformation—especially in areas of manufacturing, inventory, and production visibility.
Key challenges included:
- Stage-wise Inventory Monitoring
Need for granular tracking of inventory at every stage of production to avoid stock misplacement or duplication. - Accurate Manufacturing Costing
Determining real-time, stage-wise production costs to help improve profitability. - Informed Procurement Planning
Inability to base purchase decisions on actual stock positions led to inefficiencies in material management. - Material Traceability
Difficulty in tracing raw materials used in each batch of finished products. - Scrap and Wastage Control
Lack of data-driven insights into scrap generation at various stages hindered production cost optimization. - Visibility into Production Progress
Managers needed real-time updates on production status, across multiple product grades and stages.
Implemented Solution
After a comprehensive “as-is” process audit and deep understanding of the client’s operations, a customized ERP solution was deployed, tailored to meet their exact manufacturing and business needs.
Core Features Implemented:
- Production Planning Integration
Planning aligned directly with consolidated sales orders, ensuring that raw material procurement and shop-floor activities reflected actual demand. - Comprehensive Material Requirement Planning (MRP)
Automated indents generated for raw materials based on production plans, ensuring timely availability and reducing manual dependency. - Stage-wise Stock Visibility
Product grade and production stage visibility was enabled without the need to create separate SKUs for each variation—reducing complexity in stock management. - Barcode-Enabled Despatch & Traceability
Each final product was tagged with a batch number and barcode, enabling traceability from raw material to finished product. - Simplified Production Accounting
Shop-floor users recorded production data via a mobile interface with touch-screen support and barcode scanning, making the process intuitive and accurate. - Real-Time Production Reporting
From latex preparation to final packaging, each stage was tracked with timestamped logs to provide accurate cost data and progress updates.
Results & Benefits
- Enhanced production efficiency and traceability through stage-wise reporting.
- Informed decision-making thanks to real-time visibility of stock and production.
- Reduced procurement errors with MRP-linked indent generation.
- Minimized wastage and scrap, resulting in improved margins.
- Improved shop floor productivity via user-friendly mobile interfaces.
Conclusion
This ERP implementation empowered a leading player in the sleep and comfort products industry to overcome legacy operational challenges and modernize their core business processes. The solution brought agility, traceability, and precision to production and inventory management—equipping the organization to scale further with confidence.