How a ceramic giant unified 9 warehouses and a 4-tier supply chain into a single digital nervous system using ERPNext.
A powerhouse in the Indian tile industry, Happy Enterprise operates on a massive scale with a state-of-the-art production unit in Morbi and headquarters in Ahmedabad. They are synonymous with quality and volume, serving 68 domestic distributors and exporting to 4 international markets.
Managing a production line that churns out 12,000+ boxes per day required a level of precision that their legacy systems simply couldn't provide.
Growth is a double-edged sword. As demand surged, operational cracks began to show. The company was running on a fragmented mix of spreadsheets and basic accounting software, leading to critical bottlenecks.
With stock split across 9 warehouses, finding specific batches was a guessing game, leading to dead stock and lost sales.
Sales teams didn't know what was in production. Planning was reactive, causing downtime on the factory floor.
Management lacked real-time profitability reports. Books were closed weeks after the month ended.
QC data was manual. Tracing a defect back to the specific production batch was nearly impossible.
We mapped the entire "Clay to Carton" process. Defined workflows for procurement, production stages, and dispatch logistics.
Digitized all 9 warehouses. Implemented bin-level tracking for raw materials and batch tracking for finished tiles.
Configured multi-level BOMs. Integrated Quality Inspections at crucial production checkpoints to catch defects early.
Rolled out the Selling module to distributors. Sales teams now had visibility into "Available to Promise" stock.
Eliminated overstocking & stockouts.
Order-to-dispatch velocity increased.
Real-time production & sales dashboards.
Struggling with inventory visibility or production planning?
Get a Production AuditERPNext allows you to define unlimited warehouses. You can track raw materials in a "Store" warehouse, move them to "WIP" (Work In Progress) during production, and finally move finished tiles to a "Finished Goods" warehouse. All movements are tracked via Stock Entries.
Yes. ERPNext calculates valuation rates based on raw material costs + operating costs (electricity, labor, rent) allocated via the Work Order. This gives you a precise cost-per-unit for every batch produced.