How Apagen Helped a Switch Manufacturer in Patparganj Fix Inventory Mismatch

Client Overview

Our client is a prominent switch manufacturing company based in Patparganj, Delhi, producing both industrial and consumer-grade electrical switches.

Over the years, they had established a strong customer base but were struggling with inventory inaccuracies, which led to inefficiencies across production, supply chain, and sales operations.

The company’s manufacturing facility in Patparganj had multiple warehouses and production lines.

While their production quality was high, inventory discrepancies, caused by fragmented tracking and manual reporting, were causing stockouts, overstocking, and delayed orders, impacting operational efficiency and customer satisfaction.

Project Overview

Apagen was approached to resolve persistent inventory mismatches and enhance operational visibility using Odoo ERP. The key goal was to provide the client with accurate, real-time inventory insights, ensuring better alignment between production schedules, raw material availability, and sales orders.

This initiative aimed to:

• Centralize all inventory and production data
• Eliminate manual errors in stock tracking
• Optimize warehouse management and production planning
• Strengthen reporting for timely business decisions

Challenges & Objectives

Challenges Identified:

• Inventory records often did not match actual stock in warehouses
• Manual spreadsheets for stock reconciliation were time-consuming and error-prone
• Lack of real-time data made it difficult for managers to make informed decisions
• Frequent stockouts and overstocking affected production schedules and profitability
• Communication gaps between production, inventory, and sales teams

Project Objectives:

• Implement a centralized ERP system for inventory and production
• Enable real-time visibility of stock across multiple warehouses and production lines
• Reduce manual reconciliation and reporting errors
• Automate inventory alerts, reorder points, and production planning
• Increase operational efficiency and minimize delays

Scope of Work

Apagen’s engagement included:

1. ERP Assessment & Strategy: Detailed study of the client’s existing inventory processes, identifying mismatch patterns and reporting gaps.
2. Module Implementation: Configuration of Inventory, Manufacturing, and Sales modules in Odoo ERP to unify operations.
3. Data Migration: Cleaning, validating, and migrating historical inventory and production data for accuracy.
4. Dashboard & Reporting: Custom dashboards providing real-time KPIs for warehouse managers, production heads, and executives.
5. Workflow Automation: Streamlining stock movements, production orders, and automated alerts.
6. Training & Support: Comprehensive training for staff to ensure smooth adoption and maximize ERP benefits.

Solution Design & Implementation

Solution Design Highlights:

• Centralized Inventory Management: Unified inventory records across warehouses and production lines.
• Real-Time Dashboards: Custom dashboards displaying stock levels, consumption trends, reorder alerts, and production schedules.
• Automation: Automated stock updates, alerts for low inventory, and synchronization with production orders to prevent mismatches.
• Integrated Workflows: Seamless connection between inventory, manufacturing, and sales operations to reduce communication gaps.

Implementation Steps:

1. Data Audit & Mapping: Conducted a thorough review of current stock data to identify inconsistencies between actual and recorded inventory.
2. ERP Configuration: Set up Odoo ERP modules for inventory, production, and sales with custom workflows tailored to the Patparganj facility.
3. Data Migration & Validation: Historical stock data was cleaned, validated, and imported to ensure accurate baseline records.
4. Workflow Automation: Enabled automatic updates for stock movement, real-time inventory alerts, and production scheduling.
5. Training & Change Management: Conducted detailed training sessions for warehouse, production, and sales teams, highlighting ERP workflows and reporting features.
6. Monitoring & Optimization: Post-implementation monitoring to fine-tune dashboards, reporting, and alert thresholds for maximum operational efficiency.

Execution Challenges

• Staff Adaptation: Transitioning from manual spreadsheets to an automated ERP system required active change management and training.
• Data Cleaning: Historical stock data had inconsistencies that needed careful validation before migration.
• Integration Complexity: Aligning inventory, production, and sales workflows across multiple departments and warehouses at the Patparganj facility.

Results & Impact

• 100% Real-Time Inventory Visibility: Managers now have complete visibility into stock levels across warehouses and production units.
• Significant Reduction in Stockouts and Overstocking: Accurate inventory tracking minimized production delays and reduced unnecessary holding costs.
• Faster Decision-Making: Automated dashboards and alerts enable managers to proactively respond to discrepancies.
• Improved Production Efficiency: Better alignment of raw material availability with production schedules reduced downtime.
• Enhanced Customer Satisfaction: On-time order fulfillment increased, strengthening client relationships.
• Scalable Operations: ERP system prepared the client for future expansion and multi-location management.

Client Feedback & Innovations

The client expressed high satisfaction with Apagen’s approach, noting that the ERP solution:

• Streamlined inventory operations and improved data accuracy
• Enabled smarter decision-making and reduced operational risks
• Opened doors for future automation initiatives, such as predictive stock replenishment and advanced analytics for demand forecasting

Key Learnings & Project Team

Key Learnings:

• Accurate data migration is critical for ERP success and decision-making reliability
• Early stakeholder engagement ensures smooth adoption across all teams
• Custom dashboards and real-time alerts drive operational efficiency

Project Team:

• ERP Consultants(1): Odoo configuration and module setup
• Data Analysts(1): Inventory audit, data cleaning, and migration
• Training Specialists(1): User onboarding, workflow training, and ongoing support

For any queries drop us a line at sales@apagen.com or call us on +91 9971800665.