How ERP helps in Quality & Compliance Challenges within Auto Parts Manufacturing

Client Overview

• Industry: Automotive spare parts manufacturing (plastic and metal components)
• Size & Location: Mid-sized manufacturer, 250+ employees, located in Patparganj, India
• Core Business Activities: Production of precision automotive components such as dashboard assemblies, gear housings, and interior trims.
• Market Relevance: Supplies critical components to leading automotive OEMs across India and Southeast Asia, requiring strict adherence to quality and regulatory standards.

The Challenge

Initial Situation:

• The client struggled with inconsistent quality checks, regulatory audits, and traceability of production batches.

Key Operational/Technical Problems:

• Manual quality inspections leading to errors and delays.
• Difficulty tracking material batches to finished components.
• Lack of automated alerts for non-compliance with automotive standards (ISO/TS 16949).
• Inefficient reporting for audits and regulatory submissions.

Pain Points & Consequences:

• Frequent rework and scrap increased production costs.
• Missed deadlines impacted OEM relationships.
• High risk of regulatory penalties and reputational damage.

Objectives & Expectations

Business Goals & KPIs:

• Achieve consistent compliance with ISO/TS 16949 standards.
• Reduce production defects and scrap rates by 30%.
• Improve audit readiness and reporting efficiency.

Stakeholder Expectations:

• Transparent visibility across production, quality, and inventory.
• Seamless integration between shop floor, ERP, and regulatory reporting.

Success Metrics Defined:

• % reduction in non-conformance incidents.
• Time saved in audit preparation.
• Improvement in first-pass yield.

Scope of Work

Departments/Modules Covered:

• Production, Quality, Inventory, Compliance, and Reporting

Processes Mapped/Automated:

• Batch traceability from raw material to finished goods
• Automated quality checks at each stage of production
• Regulatory reporting and documentation workflows

Complexity:

• Multi-shift production with multiple molding machines
• Compliance tracking for ISO and automotive-specific regulations
• Custom workflows for non-conformance management

Solution Implementation

ERP Modules or Tools Used:

• Odoo Manufacturing (MRP), Quality, Inventory, and Reporting modules

Key Configurations/Customizations:

• Automated QC checkpoints integrated into production orders
• Batch traceability and serial number assignment for all components
• Regulatory compliance dashboards with alerts for deviations

Automation & Integrations Implemented:

• Real-time shop floor data capture via IoT-enabled devices
• Integration with inventory and purchasing to ensure material compliance
• Auto-generation of audit reports for regulatory bodies

Execution Challenges

Roadblocks During Implementation:

• Resistance from operators accustomed to manual QC processes
• Integration of legacy machine data with Odoo ERP

User Adoption Issues/System Constraints:

• Initial confusion in following automated QC workflows
• Limited technical knowledge among some staff

Resolution/Mitigation:

• Conducted hands-on training sessions and SOP workshops
• Customized dashboards to simplify monitoring
• Gradual rollout of automation across shifts

Results & Business Impact

Quantitative Results:

• 35% reduction in production defects within first 3 months
• 40% faster audit preparation and reporting turnaround
• 30% reduction in scrap and rework costs

Operational Improvements:

• Real-time visibility of quality metrics across all production lines
• Early detection of non-compliance issues, preventing regulatory penalties

Strategic/Long-Term Benefits:

• Improved OEM relationships due to consistent quality delivery
• Standardized quality processes embedded for future scalability

Client Feedback

"With Apagen¡¯s Odoo solution, we finally have full control over our quality processes. Non-compliance risks are minimized, and audits are now stress-free. Our production teams are more confident and efficient than ever."

¡ª Head of Operations, Auto Parts Manufacturer

Key Innovations

• End-to-end batch traceability with real-time alerts for non-compliance
• Automated QC workflows integrated seamlessly with manufacturing orders
• Custom dashboards for regulatory and quality KPIs
• Hands-on training and change management to ensure adoption

Apagen¡¯s Odoo ERP implementation transformed the client¡¯s quality and compliance management. Production efficiency improved by 45%, defects dropped significantly, and audit processes became faster and more reliable.

Next Steps:

The client plans to extend Odoo ERP to integrate predictive maintenance, further reducing downtime and enhancing regulatory adherence.

To achieve this kind of business excellence just drop us an email at sales@apagen.com or call us on +91 9971800665.