Shop-floor ERP that replaced 27 spreadsheets
A precision components manufacturer ran production on spreadsheets and WhatsApp. We built one system for job cards, inventory and dispatch.
Client Feedback
“For the first time in 22 years I can see the whole plant on one screen. From anywhere.”
Mahesh Patel
Managing Director, Kalpataru Industries
Measurable business results
-87%
Late dispatches
₹42L
Annual savings
4 days → 0
MIS reporting time
312
Daily active shop-floor users
The Problem
Production planning lived in 27 spreadsheets. Stock counts were three days stale, and 11% of orders shipped late because nobody knew a machine was free.
Before our intervention:
- 27 spreadsheets, 3-day-old stock data
- 11% late dispatch rate
- Manual monthly MIS taking 4 days
The Outcome
Line-by-line rollout with floor champions trained first, then a hard spreadsheet cutoff.
After launch:
- Single live system
- 1.4% late dispatch rate
- MIS generated instantly
How we designed and engineered it
Discovery & Insights
Six weeks of process mapping across three shifts. We timed every handoff and found 40% of supervisor time went to chasing information, not decisions.
UX & System Design
A dense, keyboard-first operations console designed for gloved hands and shop-floor tablets — high contrast, large targets, no hidden menus.
Engineering & Quality
Event-sourced job tracking, offline-tolerant tablet clients, barcode scanning and a reporting layer finance could trust.
Services Delivered
Technology Stack
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