Client: Leading Indian Switchgear Manufacturer Industry: Electrical Equipment and Switchgear Manufacturing ERP Solution: Odoo ERP (Manufacturing, Inventory, Sales, Purchase, Accounting, Quality, Maintenance) ERP Partner: Apagen Solutions Implementation Timeline: 5 Months Location: India (Gurugram)
Executive Summary
A well-established switchgear manufacturing company in India faced serious challenges due to its reliance on Excel spreadsheets and manual processes. These outdated systems led to production delays, stock mismatches, and inefficient communication between departments.
With Apagen Solutions as their technology partner, the client embarked on a digital transformation journey by implementing Odoo ERP. In just five months, they successfully moved from disconnected spreadsheets to a centralized and automated ERP platform. The result was improved operational efficiency, better inventory control, faster decision-making, and enhanced collaboration across departments.
About the Client
The client is a mid-sized manufacturer of electrical switchgear products that are used in residential, industrial, and government projects. Their operations include in-house production, multiple vendors, a large inventory, and project-based B2B sales. With more than 180 employees and a product line covering low and medium-voltage switchgear units, their day-to-day operations are complex and demand real-time coordination.
Business Challenges
Despite having an experienced workforce and a growing customer base, the client’s internal processes were disjointed and heavily manual. Some of the major challenges included:
Disjointed Systems Each department worked in isolation using separate Excel files. Sales, purchase, accounts, and production teams often had conflicting data. This led to miscommunication, errors in orders, and unnecessary delays.
Manual Production Planning Production scheduling was done manually, often based on outdated information. There was no structured material requirement planning system. This resulted in raw material shortages, delayed deliveries, and overproduction of some items.
Lack of Real-Time Inventory Visibility The warehouse team struggled to track available stock. Audits were time-consuming, and stock mismatches were frequent, causing disruptions in production.
Inefficient Quality Control Quality checks were recorded on paper, which made it difficult to trace product quality over time or link test results to suppliers and batches.
Delayed Reports and Decision-Making Generating customer quotes, creating reports, or analyzing business data required a lot of manual effort. Weekly reports for management could take several hours to prepare.
These challenges affected customer satisfaction, operational efficiency, and profitability. The leadership team knew they had to act fast to remain competitive and scale their business.
Our Approach
Apagen Solutions followed a structured implementation process with strong involvement from all stakeholders.
Step 1: Requirement Analysis Our team conducted a two-week deep-dive into the client’s existing processes. We worked closely with department heads to map current workflows and identify inefficiencies.
Step 2: ERP Design and Customization We proposed a complete Odoo ERP suite tailored to their operations. This included modules for manufacturing, inventory, sales, purchase, accounting, quality, and maintenance. We also recommended specific customizations, such as barcode tracking, quality control forms, and dashboard reports.
Step 3: Data Migration All relevant data from Excel files, including vendors, inventory, bill of materials, open orders, and customer information, was validated and imported into the new system.
Step 4: User Training and Go-Live We trained department-wise teams on how to use Odoo ERP effectively. The go-live was done in phases, beginning with inventory and sales, followed by manufacturing and finance.
ERP Modules Implemented
Manufacturing (MRP) We implemented automated work orders based on sales orders. Multi-level bills of materials were configured, and production routes were set up for each assembly line.
Inventory Management We introduced barcode scanning, batch tracking, and warehouse zones. Real-time inventory dashboards enabled faster decision-making and reduced stock discrepancies.
Sales and Purchase Sales and purchase processes were integrated with inventory and manufacturing. Requests for quotation and purchase orders were generated automatically. Approval workflows ensured accountability.
Accounting Odoo’s accounting module helped automate journal entries, invoicing, and GST compliance. The finance team gained better visibility over receivables, payables, and bank reconciliation.
Quality Management We configured quality checkpoints at multiple stages including raw material receipt, in-process checks, and final product inspection. Test results were stored digitally and linked to specific batches.
Results Delivered
After three months of going live, the client experienced major improvements in day-to-day operations. Some measurable outcomes included:
- Production planning shifted from manual to system-driven, improving efficiency and delivery timelines
- Inventory accuracy improved from around 75 percent to over 98 percent
- Reports that previously took several hours to prepare were now available instantly via dashboards
- Stock mismatches and delays in raw material procurement were significantly reduced
- Traceability of quality issues became easier due to digital QC records
- Customer response times improved as sales teams had quicker access to inventory and order status
Before ERP, average order fulfillment time was 7 to 10 days. After Odoo implementation, it reduced to 4 to 6 days.
Client Feedback
The Plant Head shared this feedback:
“We were hesitant at first, but Apagen’s team handled the process with professionalism and clarity. Our shop floor team can now see work orders in real-time, our stock team has better control, and our finance team spends far less time generating reports. We have full visibility across our business like never before.”
Conclusion
This successful implementation is a great example of how a mid-sized manufacturing company can transition from basic spreadsheets to a powerful ERP platform. The move to Odoo ERP helped the client achieve process integration, data accuracy, faster decision-making, and better customer service.
By eliminating manual tasks and improving collaboration, the business is now well-positioned to scale operations, take on larger orders, and respond to market demands more efficiently.
About Apagen Solutions
Apagen Solutions is a trusted Odoo ERP implementation partner for manufacturing companies across India. Our deep understanding of industrial workflows, combined with technical expertise, allows us to deliver customized ERP systems that transform the way businesses operate.
We offer consulting, implementation, support, and training for clients in various industries including electrical, mechanical, food processing, metal fabrication, and more.
If you are ready to streamline your business with Odoo ERP, reach out to us for a free personalize live demo/consultation.
Visit www.apagen.com or email us at Sales@apagen.com
