How AutoTech Components Reduced Inventory Costs by 32% with ERPDrive

AutoTech Components Pvt Ltd is a Pune-based manufacturer that produces brake components - brake discs, brake drums, and caliper assemblies - for Tier-1 OEM suppliers in India's automotive sector. With 85 employees across their production facility, the company had grown steadily over the past decade.

But their systems had not kept pace with their growth. The entire operation ran on a combination of Tally for accounting, Excel spreadsheets for production planning and BOMs, and WhatsApp groups for coordinating between the shop floor and front office. This patchwork approach was creating serious operational problems.

• No production planning system: Production schedules were maintained on whiteboards and updated manually every morning. Changes during the day were communicated over WhatsApp, leading to confusion and missed jobs.
• BOMs managed in spreadsheets: Bill of materials for over 140 products were tracked across multiple Excel files. Version control was non-existent, and the wrong BOM was used in production at least twice a month.
• 18% rejection rate: Without a formal quality control system, defective parts were not caught until final inspection or, worse, at the customer end. Rejection rates were averaging 18%, well above the industry norm.
• 28% overdue orders: Late deliveries had become routine, with 28% of orders shipping past their committed delivery dates. Two key OEM customers had issued formal warnings about delivery performance.
• Excess inventory worth ₹45 lakhs: Without visibility into actual requirements versus stock levels, the purchasing team over-ordered raw materials as a buffer. Dead stock and excess inventory had ballooned to ₹45 lakhs.

Within three months of going live, AutoTech Components saw measurable improvements across every key operational metric. The numbers speak for themselves.