Project Name
Odoo 19 ERP Implementation for a Specialised Seating Manufacturer in India
Our client is an India-based specialised manufacturer of high-performance seating systems engineered for the country’s most demanding mobility and infrastructure sectors. Their products power flagship national programmes including the Vande Bharat Express: premium seating for India’s flagship semi-high-speed train, and the Amrit Bharat: robust seating systems for long-distance superfast trains, alongside mission-critical applications in marine vessels, defence platforms, and earthmoving equipment built for harsh operating environments.
The business runs on long-cycle, make-to-order project manufacturing with rigorous compliance and traceability requirements across four sectors: Railways, Marine, Defence, and Earthmovers. Prior to this engagement, operations were straining under fragmented systems and manual workflows with no centralised platform connecting sales, production, inventory, quality, and finance into a single source of truth.
Twelve operational pain points across fragmented systems, manual production planning, limited inventory visibility, quality gaps, approval bottlenecks, and the absence of project-level costing.
- Lack of a Centralised System: Sales, purchase, production, and finance data were spread across spreadsheets and standalone applications, making it difficult to maintain a single view of the order-to-delivery cycle.
- Manual Production Planning: Multi-level BOMs, work orders, and routings were managed in spreadsheets, creating version conflicts and making it difficult to respond to changing demand or material availability.
- Inventory Visibility Gaps: The business lacked real-time visibility into raw materials, WIP, and finished goods, leading to stockouts, excess inventory, and last-minute procurement.
- Challenges in Stock Transfers: Material movements between incoming, sub-assembly, finishing, and dispatch locations relied on manual entries, causing delays and inaccurate stock records.
- Negative Stock Levels: Issuing materials before recording receipts frequently resulted in negative stock, making availability reports unreliable and increasing reconciliation efforts.
- Quality Compliance Gaps: Manual QC checklists made it difficult to identify non-conformances early, maintain audit trails, and trace finished seats back to component lots.
- User Permission Management: Without role-based access, unauthorised or accidental changes to purchase orders, inventory, and financial records could go unnoticed.
- Uncontrolled Approvals: Purchase, change, and production approvals moved through email and paper, with no central audit trail, automated escalation, or visibility into pending requests.
- Manual Journal Entries: Finance teams manually recorded entries for product movements, intercompany transfers, and stock adjustments, increasing errors and extending the month-end close.
- No Project-Level Costing: Existing systems could not consolidate material, labour, overhead, freight, and duties into true project costs, leaving margins largely estimated.
- Reactive Financial Reporting: Disconnected invoicing, vendor bills, taxes, and banking systems required days of manual consolidation, limiting access to real-time financial insights.
- Inadequate Reporting and Documents: Standard reports and documents required extensive manual formatting, making it difficult to generate customised, sector-specific, and programme-level outputs.
Ksolves, an AI-first Odoo development company, implemented a unified Odoo 19 Enterprise ERP through a phased, module-by-module approach, configuring seven integrated applications around the client's make-to-order manufacturing model. Each module addressed a specific operational challenge, with end-to-end integrations validated before go-live.
- Unified Cloud ERP: Deployed Odoo 19 as a single cloud ERP, centralising sales, purchase, production, inventory, quality, and finance data with role-based access.
- MRP-Driven Production: Configured multi-level BOMs, routings, and work centres for all seat variants, with automated manufacturing orders, capacity-based scheduling, and live Gantt planning.
- Multi-Location Inventory: Structured warehouses and internal locations for raw materials, sub-assembly, finishing, and finished goods, with real-time stock, lot/serial tracking, and automated reorder rules.
- Streamlined Stock Transfers: Configured internal routes, push/pull rules, and barcode-friendly operations to record stock movements instantly and provide one-click component traceability.
- Negative Stock Controls: Implemented validation rules and negative-stock controls to prevent excess issuance, with alerts notifying supervisors before negative balances occur.
- Compliance-Grade Quality: Configured QC checkpoints for incoming, in-process, and finished goods, with mandatory inspections, non-conformance alerts, and complete audit histories.
- Role-Based Access Control: Defined granular user roles and record-level permissions for each module, ensuring controlled access and accountability for every system change.
- Automated Approval Workflows: Configured multi-step approvals for purchase orders, expenses, design changes, and internal transfers, replacing email-based approvals with digital sign-offs and audit trails.
- Automated Journal Entries: Automated accounting entries for stock movements, manufacturing, shipments, and receipts, reducing manual reclassifications and accelerating month-end closing.
- Project Costing and Landed Cost: Enabled project and landed-cost tracking to consolidate material, labour, overhead, and freight costs, giving leadership accurate programme-level margins.
- Integrated Accounting: Centralised invoicing, vendor bills, taxes, and bank reconciliation within Odoo, with real-time financial dashboards by project, customer, and sector.
- Custom Reports and Documents: Developed branded templates for quotations, purchase orders, delivery challans, invoices, and management reports, enabling professional, audit-ready outputs with one click.
Technology Stack
| Category | Technology |
|---|---|
| Platform | Odoo 19 Enterprise |
| Modules | Sales, Purchase, Inventory, Manufacturing, Quality, Approvals, and Accounting |
From fragmented, manual operations to a connected, audit-ready Odoo 19 platform integrating all seven functions.
- Single Platform Unifying Seven Functions: Sales, purchase, inventory, manufacturing, quality, approvals, and accounting now operate on one shared ERP, providing a unified view of operations.
- Faster Order-to-Make – Planning Lag Eliminated: Sales orders flow directly into MRP, automatically generating manufacturing orders and enabling capacity-based scheduling with live Gantt planning.
- 100% Lot Traceability, From Raw Material to Delivered Seat: End-to-end lot and serial tracking now covers material receipt, production, QC, and delivery, with traceability available through a single report.
- Compliant Quality, Railway and Defence Standards Enforced by Design: Mandatory QC checkpoints, failure alerts, and complete inspection histories strengthen compliance and ensure non-conformances are addressed before the next stage.
- Tighter Stock Discipline – Real-Time Visibility Across All Locations: Real-time inventory visibility, MRP-linked reorder rules, and negative stock controls improve stock accuracy across all locations and reduce reconciliation efforts.
- Approvals Routed, Recorded, and Reportable: Multi-step approval workflows with escalation and digital sign-offs replace email and paper-based approvals, creating clear accountability and audit trails.
- Automated Journals Cut Month-End Consolidation: Automated journal entries for stock and production transactions reduce manual consolidation and help finance close periods faster.
- Landed Cost Surfaces Real Programme Profitability: Material, labour, overhead, and freight costs now roll up by project, giving leadership accurate programme-level margins for better pricing decisions.
Ksolves transformed a fragmented, spreadsheet-driven manufacturing operation into a unified, audit-ready Odoo 19 platform. By connecting sales, procurement, MRP, inventory, quality, approvals, and accounting, the implementation delivers real-time traceability, stronger compliance, faster planning, and accurate project-level costing. With every transaction captured on a shared system, the business can operate with greater control today and scale confidently across future railway, marine, defence, and industrial programmes.
Are BOM Version Conflicts and Manual Work Orders Still Slowing Down Your Shop Floor Planning?
