Improved production, inventory, and dispatch tracking for electrical manufacturing with better material visibility and control.

Transforming Production Accuracy & Inventory Control for an Electrical Components Manufacturer Using Zventory (AI Powered)

Industry: Electrical Components (Switchgear, Wiring Accessories, PCB Assemblies)

Company Size: Mid-scale manufacturing with 3 units

Modules Used: Inventory, Purchase, Production, Sales, Dispatch, DMS, HR

Key Challenges: Batch tracking, raw material mismatch, delayed production, purchase misalignment, reporting issues

Background

An electrical components manufacturing company producing switchgear items, PCB assemblies, wiring accessories, and control panel parts faced growing operational challenges as their production volume increased.

With multiple production lines, hundreds of batch-sensitive components, and frequent customer orders, they struggled to maintain accurate stock, efficiently track materials, and ensure timely deliveries.

The management realized that spreadsheets and legacy software were no longer sufficient. They needed an integrated solution that could streamline inventory, predict material shortages, automate purchase planning, and track production in real-time.

This is when they implemented the Zventory (AI Powered), which transformed their operations significantly.

The Challenges

1. Inaccurate Batch-wise Tracking

Most electrical components have batch numbers, especially resistors, capacitors, ICs, metal parts, and PCBs.

However, the company tracked materials manually, causing:

• Frequent stock mismatches
• Incorrect batch allocation
• Compliance issues during audits
• Delays in quality verification

2. Production Delays

Production was frequently halted because raw materials were either:

• Overbooked
• Understocked
• Incorrectly allotted
• Stored in another warehouse without visibility

This caused unpredictable timelines and customer dissatisfaction.

3. Unplanned Procurement

The purchasing team often placed purchase orders late because they didn’t know:

• How much material was allotted to ongoing production
• What stock was actually available
• Which materials were running low

Lack of automated purchase planning led to downtime in production lines.

4. No Visibility Across Branches

The company operated across three units:

• Pune Warehouse
• Mumbai Warehouse
• Bangalore Warehouse

But the stock transfer system was manual, and reports were not centralized.

The Solution Implemented

The company adopted the Zventory (AI Powered), enabling a unified ecosystem for sales, purchase, manufacturing, stock, and dispatch.

✔ Batch-wise Inventory Management

Every component was now tagged with:

• Batch Number
• Serial Number (where applicable)
• Expiry / Quality Check Date

The ERP automated:

• Stock inward (Purchase Material Inward)
• Stock outward
• Batch-to-production allotment
• Batch-level traceability

This created accurate, audit-ready tracking.

✔ Real-time Production Tracking

The entire production workflow was digitized:

• Start Production
• Running Production
• Pending Production
• Finished Production

Each production job automatically pulled required materials from the BOM, showing:

• What’s in stock
• What’s insufficient
• What needs to be purchased

✔ Automated Purchase Indents

When production required materials, the system auto-generated:

• Purchase Indents
• Notifications to the Purchase Department
• AI-based forecasting for the next purchase cycle

This ensured materials were ordered well before stockouts.

✔ Dashboard for Multi-Unit Visibility

The new dashboard provided real-time access to:

• Total productions
• Running orders
• Pending orders
• Total sales & returns
• Low stock updates
• Purchase & dispatch statistics

The Results

1. 40% Reduction in Material Shortages

With batch-wise tracking and stock visibility, the company eliminated stock confusion and production stoppages.

2. Production Timeliness Improved to 95%

Because required materials were always planned in advance, production delays dropped drastically.

3. 100% Accuracy in Batch Traceability

During audits and customer QC inspections, the company could instantly provide:

• Batch history
• Inspection documents
• Production logs

This built greater customer confidence.

4. 60% Faster Purchase Cycles

Auto Purchase Indents and AI forecasting ensured purchasing always stayed ahead of production demand.

5. Centralized Multi-Branch Operations

Movement of components between warehouses and units became fully trackable and transparent.

Conclusion

The Zventory (AI Powered) system became a critical part of the company’s success by delivering:

• Production clarity
• Better inventory planning
• Zero stock mismatch
• Faster purchase cycles
• Improved customer delivery commitments

Today, the company handles higher volumes with precision and confidence, thanks to a complete digital transformation.