Project Name
Odoo 19 ERP Implementation for a Leading Automotive Coil Spring and Oil-Tempered Wire Manufacturer
Our client is a leading Indian manufacturer of oil-tempered wires and cold-coiled suspension springs for the auto-component sector, operating a green-field manufacturing facility of approximately 10,000 square metres with a continuous piece-flow line. With an annual production capacity of 1.5 million-plus springs across 8 to 16 mm wire diameters, the organisation serves customers across the Trucking, Automotive, Defence, Construction, and Mining sectors.
As volumes grew, the gap between the business’s operational complexity and its fragmented tooling became structurally unsustainable, and the organisation engaged Ksolves to modernise all operations on a single Odoo 19 platform.
The business needed a connected, scalable system to streamline operations, improve visibility, and support faster, data-driven decision-making.
- Disconnected Systems: Sales, purchase, stock, and accounts operated across spreadsheets and standalone tools, leaving no single source of truth and making management reporting manual.
- No Stock Visibility: Raw-material coils and finished springs were difficult to track in real time, causing overstocking, shortages, and poor production planning.
- Manual Production Planning: Work orders and shop-floor schedules were managed manually, making it difficult to align production with sales commitments or demand changes.
- Weak BOM Control: Without structured Bills of Materials, material consumption and production variances were difficult to measure, weakening costing and planning.
- Uncontrolled Procurement: Purchase requests, vendor pricing, and PO approvals lacked standard workflows, causing delays, maverick buying, and limited auditability.
- Fragmented Orders: Quotations, sales orders, and dispatch details were maintained separately, slowing customer responses and making order tracking manual.
- Costing Blind Spots: Material and process costs were difficult to calculate accurately, weakening pricing decisions and margin visibility across products.
- Delayed Reporting: Management reports were compiled manually, delaying critical operational and financial decisions.
- Reactive Replenishment: Reorder decisions relied on manual judgment, increasing stockout risks and tying up working capital.
- Traceability Gaps: Linking raw-material batches to finished production runs was difficult, creating compliance and quality-tracking challenges.
- Manual Accounting: Invoicing, journal entries, and reconciliation remained largely manual, increasing effort and the risk of financial errors.
- Limited Scalability: The existing setup could not support growing volumes without increasing manual effort and headcount, limiting sustainable business growth.
Ksolves, an AI-first Odoo implementation partner, implemented Odoo 19 as a single, connected ERP across five core business functions, replacing scattered tools with one real-time system. The approach was configure-first, using standard Odoo capabilities wherever possible and targeted customisation only where required.
- Sales Order Management: A structured quotation-to-order flow with centralised customer data and consistent pricing, enabling faster, controlled responses from enquiry to confirmed order.
- Live Sales Reporting: Real-time dashboards for orders, revenue, and product mix, giving management an accurate view of sales without manual report compilation.
- Procurement Flow: Standardised requisitions and PO approvals replace ad-hoc buying with controlled, auditable procurement, reducing delays and maverick purchases.
- Vendor Management: A central vendor master with price lists enables consistent sourcing and easier supplier comparison, supporting structured vendor evaluation.
- Real-Time Stock Visibility: Multi-location tracking provides live visibility of wire, raw materials, and finished goods, replacing manual stock estimation with accurate inventory data.
- Smart Replenishment: Reordering rules and warehouse operations help prevent stockouts and excess inventory, reducing unnecessary working-capital lockup.
- Multi-Level BOMs: Multi-level Bills of Materials capture material and component requirements for each spring variant, supporting consumption tracking, variance analysis, and accurate costing.
- Manufacturing and Work Orders: Manufacturing and work orders reflect the shop floor, coiling, tempering, shot-peening, and testing, replacing manual production control with structured workflows.
- Demand-Aligned Production Planning: Production planning aligns with sales demand and material availability, improving workflow and supporting more reliable customer commitments.
- Automated Journal Entries: Invoices and journal entries flow automatically from sales, purchase, and inventory movements, reducing manual accounting effort and period-close errors.
- GST and Tax Compliance: Built-in GST and financial reporting support faster, compliant period closes, replacing manual tax compilation with system-driven processes.
- Product Costing: Material and process costs are linked to production runs, improving pricing and margin decisions with reliable product cost data.
Technology Stack
| Category | Technology |
|---|---|
| Platform | Odoo 19 |
| Module | Odoo Sales |
| Module | Odoo Inventory |
| Module | Odoo Purchase |
| Module | Odoo Manufacturing |
| Module | Odoo Accounting |
The Odoo 19 implementation transformed fragmented operations into a connected, data-driven business with greater visibility, control, and efficiency.
- Single Source of Truth Established: Sales, purchase, inventory, production, and finance now operate on one connected, real-time system, eliminating fragmented data and manual cross-functional reconciliation.
- Real-Time Stock Control, Fewer Shortages and Excess: Live visibility of raw materials and finished goods replaces manual stock tracking, helping production and procurement respond to current inventory positions.
- Structured Production, BOM-Driven Manufacturing: BOM-driven manufacturing and work orders provide clear material consumption and output tracking, replacing manual planning with measurable, system-controlled production.
- Disciplined Procurement - Controlled, Auditable Buying: Standard requisition and PO approval workflows enable faster, controlled procurement, reducing delays, maverick buying, and unnecessary costs.
- Accurate Product Costing: Product-level costing links material and process costs to each production run, enabling sharper pricing and clearer margin visibility.
- Faster Reporting: Automated accounting and live dashboards replace manual report compilation, giving management timely visibility into orders, revenue, inventory, and financials.
For a high-volume spring manufacturer, spreadsheets and disconnected tools had become a barrier to visibility, control, and scalable growth. Ksolves implemented Odoo 19 to bring sales, procurement, inventory, manufacturing, and accounting onto one connected platform. The result is a more structured, data-driven operation with real-time stock visibility, BOM-controlled production, disciplined procurement, accurate costing, and faster reporting. Odoo 19 now provides the connected foundation the business needs to scale with greater confidence and control.
Is Your Manufacturing Operation Still Running Across Spreadsheets?
