Production planning in one tool, inventory in another, dispatch on WhatsApp, and finance reconciling all of it manually every month. Growth had turned coordination into the plant's biggest bottleneck.
A modular custom ERP built around their actual order-to-dispatch flow: sales orders, production scheduling against furnace capacity, stores and scrap accounting, quality gates, dispatch with e-way integration, and a finance layer that reconciles automatically.
The breaking point
Every month-end, finance chased production for numbers that never matched stores. Dispatch commitments were made from memory. The group knew an off-the-shelf ERP would force their process into someone else's template — they'd tried once and abandoned it.
Engineering to the process
We spent four weeks on the shop floor before proposing a single module. The resulting system mirrors how material actually moves — heats, batches, yields, scrap — so operators log reality, not approximations. Adoption followed because the software finally agreed with the floor.
Compounding returns
With one source of truth, closing accelerated, discrepancies surfaced in hours instead of quarters, and management got morning dashboards that used to take three analysts a week to compile.