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Manufacturing

Three plants running on one production system

Multi-plant BOM, quality control, and shop-floor reporting unified on a single ERPNext instance.

ClientNational auto-parts manufacturer with three plants in West Java
IndustryManufacturing
Timeline9 months
Team8 specialists
0
Plants unified
0%
Lower scrap rate
0×
Faster WIP visibility
The challenge

The company supplied five national assemblers under strict just-in-time contracts, but each plant planned production in its own spreadsheet. Head office only learned about a material shortage when a line had already stopped.

01Bills of material lived in engineering spreadsheets, so costing used last year prices and quoted margins were guesswork.
02Work-in-progress was invisible between plants; expediting a late order meant phone calls to three production supervisors.
03Quality inspections were recorded on paper and filed, making root-cause analysis on recurring defects effectively impossible.
04Suppliers sent delivery confirmations by WhatsApp and email, and purchasing re-keyed every one into a spreadsheet.
Our approach

The solution

ERPNext implementation

We rolled out ERPNext Manufacturing across all three plants on a single instance, with each plant as its own warehouse group and cost centre so consolidated reporting works without extra effort.

ERPNext modules
Manufacturing
Stock
Quality
Buying
Accounts
Assets
Highlights
Multi-level BOMs with routing, workstation costing, and automatic scrap and rework accounting.Material Requirements Planning driven by real assembler forecasts instead of manual reorder points.Quality Inspection templates tied to incoming goods, in-process checks, and final release.Coretax e-Faktur integration so PPN output invoices are generated straight from Sales Invoices.

Web platform

A supplier portal where the company 140 vendors see purchase orders, confirm delivery dates, upload delivery notes, and track invoice payment status without emailing purchasing.

Key features
PO acknowledgement with committed delivery dates that write straight back to ERPNext
Vendor upload for surat jalan, packing lists, and certificates of analysis
Live supplier scorecard showing on-time delivery, rejection rate, and quality holds
Payment status and remittance advice, cutting invoice-chasing calls to finance
Stack
Next.jsReactNode.jsPostgreSQLRedis

Mobile app

Rugged Android tablets at every workstation let operators declare production, log downtime reasons, and raise quality holds without leaving the line.

Key features
Barcode job-card scanning to start, pause, and finish operations in real time
Downtime and reject logging with photo evidence attached to the work order
In-process QC checklists that block the next operation until a supervisor signs off
Offline queue so tablets keep recording through plant Wi-Fi dropouts
Stack
FlutterSQLiteMQTTFrappe REST API
Results

Business outcomes

0%
Lower scrap rate
0%
On-time delivery
0
Suppliers on the portal
0 days
Month-end close
Head office sees true production cost per part number the day a batch closes.
Just-in-time penalties from assemblers dropped to zero across two consecutive contract audits.
Purchasing renegotiated terms with underperforming vendors using twelve months of hard scorecard data.
A fourth plant was brought live in six weeks using exactly the same configuration.
We used to argue about whose spreadsheet was right. Now the plant floor, purchasing, and finance all look at the same work order, and the argument is over.
HHead of ManufacturingNational auto-parts manufacturer · National auto-parts manufacturer with three plants in West Java

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