How SAP Business One Helped Optimize End to End Business Processes

A leading manufacturing company with over 15 years of experience specializes in the production of high-performance composite patterns, molds, and components for OEMs in industries such as wind energy, mass transportation, and industrial equipment. Headquartered in India, the company operates five manufacturing units across the country, with a workforce exceeding 1,800 employees.

Industry: Manufacturing
ERP Solution: SAP Business One
Implementation Partner: SAP Implementation

Overview

To support its growing operations, the organization was using a legacy system that lacked integration, standardization, and control. The company sought a centralized ERP solution to streamline processes and ensure data accuracy across all branches.

Challenges Before SAP Business One

Unsystematic Procurement Approvals

Approvals were handled manually, leading to stock inflation and unnecessary procurement expenses.

Inefficient Purchase Consolidation

Multiple purchase indents for the same item couldn’t be merged into a single purchase order.

Manual Quality Control

Inward and final quality checks were managed through spreadsheets, resulting in inconsistent tracking.

Lack of Production Integration

Existing systems couldn’t support real-time integration with the production module, affecting planning and accountability.

Poor Inventory Visibility

Inaccurate stock records led to challenges in procurement optimization and production scheduling.

Limited Reporting Capabilities:

Critical analytical reports like BOM vs. actual consumption, WIP stock, and production returns were not available.

Implemented Solution and Benefits

To address these gaps, the organization implemented SAP Business One, tailored to meet their manufacturing and operational needs.

Centralized procurement approval workflows
Automated inward and final quality control via QC quarantine warehouses
Real-time inward quality analysis by item and predefined parameters
Custom solutions for returnable and non-returnable item tracking
Procurement optimization and SKU management
Minimum/maximum stock alerts and planning
Semi-customized production module with accurate cost tracking (WIP, scrap, FG)
Accurate BOM vs. actual cost comparison

Conclusion

The implementation of SAP Business One transformed the organization’s operations across all locations. By moving away from scattered legacy systems to a centralized ERP solution, the company now enjoys better visibility, control, and efficiency in procurement, inventory, sales, finance, and production.

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