Challenges & Solution
Challenges
Operations lacked control over slab-level inventory, making it difficult to track materials by size, finish and lot, leading to incorrect stock commitments and delivery issues. During yard selection, there was no system to map selected slabs to sales orders, causing duplicate allocation and confusion at dispatch.
Maintaining lot consistency was a major challenge, with different shades and patterns getting mixed, impacting customer expectations. On the procurement side, there was no visibility on import shipments and landed costs, resulting in pricing inaccuracies.
Warehouse processes were manual, with inconsistent square feet measurements, leading to billing mismatches. Additionally, there was no structured approach for average costing, making it difficult to derive accurate product valuation.
From an HR perspective, salary rule configurations were not standardized, leading to inconsistencies in payroll calculations and compliance concerns.
Solution
Implemented a centralized ERP system with detailed slab-level inventory tracking, capturing size, finish, lot and location for accurate stock visibility.
Enabled yard-based slab allocation, directly linking selected materials to sales orders, eliminating duplication and ensuring precise dispatch. Introduced lot-wise tracking to maintain consistency across deliveries.
Streamlined procurement with import tracking and landed cost management, along with average costing methods to ensure accurate inventory valuation and pricing decisions.
Automated measurement-based billing, reducing errors in invoicing and improving warehouse efficiency. Configured structured salary rules within the HR module to ensure accurate, consistent and compliant payroll processing.