Client & Project Overview
Our client is a leading manufacturer of electrical components, specializing in precision injection-moulded parts for electronics, automotive, appliances, and FMCG sectors.
With decades of experience and state-of-the-art facilities, they have earned a reputation for quality, precision, and innovation. Their operations span multiple manufacturing units with highly automated CNC machinery, producing complex components at scale.
The client had already embarked on implementing Odoo ERP to unify operations, streamline workflows, and improve reporting.
However, they faced a critical roadblock: limited in-house expertise in both Odoo ERP development and quality assurance specific to the electrical component manufacturing domain.
They required specialized customizations to meet operational and compliance needs, and needed experienced resources quickly to keep their ERP project on track.
Our mission was clear: bridge the ERP skill gaps, provide domain-specific expertise, and deliver a customized, compliant, and fully functional Odoo ERP system using staff augmentation.
Challenges & Objectives
Challenges:
- Skill Shortages: Lack of developers and QA specialists with Odoo ERP expertise tailored to electrical component manufacturing.
- Complex Workflows: Production processes with multiple product lines required ERP customizations beyond standard modules.
- Compliance Needs: Accurate reporting and quality checks were critical for industrial and regulatory standards.
- Timeline Pressure: Delays in ERP development could impact production planning, inventory management, and operational efficiency.
Objectives:
- Rapidly scale ERP development capacity with specialized staff.
- Ensure ERP modules align with production workflows and compliance requirements.
- Deliver a fully customized and functional Odoo ERP system on schedule.
- Maintain high-quality implementation through thorough QA and validation.
Scope of Work
- Customization of Odoo ERP modules (Manufacturing, Inventory, Quality, Sales).
- Staff augmentation with Odoo developers and QA specialists experienced in manufacturing ERP implementations.
- Integration of client-specific workflows and compliance protocols into the ERP system.
- End-to-end support, including deployment, user training, and post-go-live stabilization.
Solution Design & Implementation
Solution Design:
We began by mapping the client¡¯s existing workflows, production schedules, and inventory processes. The focus was on creating an ERP system that mirrored their operations while introducing automation for efficiency and compliance.
Key design elements included:
- Custom production scheduling for multiple product lines.
- Inventory management adapted for high-precision electrical components.
- Quality assurance checks embedded within ERP workflows.
- Dashboards for real-time production and inventory insights.
Stage-Wise Implementation Steps
Stage 1: ERP Gap Analysis
- Conducted a detailed assessment of the existing ERP setup.
- Identified gaps in functionality, workflow alignment, and compliance requirements.
- Documented customization needs and potential integration challenges.
Stage 2: Staff Augmentation Onboarding
- Deployed a dedicated team of Odoo developers and QA specialists with manufacturing domain knowledge.
- Coordinated onboarding and orientation with the client¡¯s in-house team.
- Assigned responsibilities for module customization, testing, and workflow analysis.
Stage 3: ERP Module Customization
- Developed tailored modules in Manufacturing, Inventory, Quality, and Sales.
- Integrated client-specific workflows, production line variations, and quality checkpoints.
- Built automated reporting for compliance, inventory tracking, and production metrics.
Stage 4: Iterative Testing & Validation
- Conducted multiple QA cycles with active client collaboration.
- Validated data accuracy, workflow alignment, and module performance.
- Addressed issues and implemented improvements in real-time.
Stage 5: Staging Deployment
- Deployed the ERP system in a controlled environment to simulate live operations.
- Monitored module interactions, production scheduling, and inventory management.
- Collected feedback from client teams to fine-tune functionalities.
Stage 6: User Training & Change Management
- Conducted hands-on training sessions for end-users across departments.
- Provided documentation, tutorials, and workflow guides.
- Facilitated smooth adoption and minimized operational disruption.
Stage 7: Go-Live & Post-Deployment Support
- Launched the ERP system across all manufacturing units.
- Ensured continuous support for troubleshooting, enhancements, and stabilization.
- Established mechanisms for ongoing maintenance, updates, and scalability.
Execution Challenges
- Modeling complex injection-moulding workflows in Odoo without disrupting production.
- Aligning ERP functionalities across multiple product categories and manufacturing units.
- Ensuring compliance and accurate reporting for quality and operational metrics.
- Coordinating seamlessly between the client¡¯s in-house team and augmented staff.
Through close collaboration and adaptive project management, these challenges were successfully addressed.
Results & Impact
- Accelerated ERP Rollout: Domain expertise in development and QA reduced project timelines.
- Fully Customized ERP: Modules perfectly aligned with production, inventory, and quality workflows.
- Improved Compliance: Embedded quality checks minimized errors and ensured regulatory adherence.
- Enhanced Operational Efficiency: Automation and dashboards provided real-time insights for better decision-making.
- Scalable System: The ERP setup now supports future growth, additional product lines, and increased production capacity.
Client Feedback & Innovations
The client expressed appreciation for the expertise, proactive problem-solving, and collaboration demonstrated by our team.
Innovations introduced:
- Automated quality checks integrated directly into ERP workflows.
- Optimized production scheduling for multiple product lines.
- Real-time inventory tracking to prevent stockouts and overstock.
The client reported greater confidence in ERP usage and noticeable improvements in operational efficiency.
Key Learnings & Project Team
Key Learnings:
- Domain expertise is essential for ERP staff augmentation in specialized manufacturing sectors.
- Early identification of gaps prevents delays and ensures smoother ERP adoption.
- Iterative testing with client collaboration is crucial for compliance and quality.
Project Team:
- 1 Project Manager: Oversaw ERP implementation and client coordination.
- 2 Odoo Developers: Specialized in manufacturing ERP customizations.
- 2 QAs Team: Focused on workflow validation and compliance.
- Client Team: Provided operational insights, validation, and user training.
Lastly, if you are looking for a staff augmentation with developers, QA, functional consultants who are specialists experienced in manufacturing ERP implementations just drop us a line at sales@apagen.com or call us on +91 9971800665.
