In the ever-evolving landscape of manufacturing, every company constantly seek ways to enhance their efficiency, improve overall productivity, reduce costs, maintain high quality, and assure their client satisfaction for a flourished future. The latest case study delves into the success story of Wahni which partnered with Cube Doors, one of the leading manufacturers of fibre- reinforced plastic doors in Kerala, revolutionizing their operations through the successful implementation of ERPNext.

About Cube Doors

A renowned manufacturer in the FRP Doors industry, Cube Doors has roots in Feroke, Calicut. Having evolved under the dynamic leadership of Mr. Saleej and Mr. Ilyas in the year 2008 they now have 100+ employees in their Head Office and 20+ franchisees across Kerala with a 25,000 sq. ft manufacturing facility. They take pride in being at the forefront of a vision that contributes to a greener and more sustainable future. Every door at Cube Doors is a testament to their dedication to precision engineering, ensuring that each product meets the highest standards of strength, resilience, and aesthetic appeal. Their doors are a statement of style and a reflection of their commitment to excellence.

At the heart of their operations is a team of skilled professionals who bring passion and expertise to every aspect of their manufacturing process. From design conceptualization to the final product, they have employed meticulous attention to detail, ensuring that their doors not only meet but exceed industry norms.

As an environmentally conscious company, they have understood the importance of sustainability in today's world. Their commitment to eco-friendly practices is evident in their use of recycled materials and energy-efficient manufacturing processes that also gave an idea of the implementation of software that could replace their habit of manual entries of every order and related paperwork.

The problems

Despite all the business they were carrying forward, Cube Doors faced many difficulties:

1. Data accuracy: This was prone to human errors, such as typos, miscalculations, and data entry mistakes.
2. Speed and efficiency: A slower process that involves physical handling of documents, filing, and searching for information.
3. Accessibility: Documents were often location-dependent, making it challenging to access information remotely.
4. Document storage and retrieval: This required physical storage space and retrieval of the involved time-consuming searches.
5. Security: This was prone to loss, damage, or unauthorized access to physical documents.
6. Costs: Involved expenses related to printing, storage, and manual labour for data entry and retrieval.
7. Scalability: Scaling operations required additional physical space, resources, and manual effort.
8. Integration with other systems: Limited integration capabilities with other systems, often lead to duplicate data entry.
9. Reporting and analytics: Generating reports involved manual compilation and analysis of data.
10. Compliance and audit trail: Compliance tracking used to be challenging, and maintaining a clear audit trail used to be labour- intensive.

This is when Wahni stepped into the picture.

The solution

In the very first meeting, Wahni learned that the time-consuming paper work was the biggest blocker for Cube Doors.They made Cube Doors realize the need for a comprehensive ERPNext solution to streamline their operations, from procurement to production and distribution. They explained how ERPNext, one-stop solution for all business processes can resolve each of their issues:

1. Data accuracy: ERPNext would provide a higher level of accuracy by automating data entry, reducing the risk of errors.
2. Speed and efficiency: ERPNext would streamline processes, enabling quick access to customer data and purchase orders, resulting in faster transaction times.
3. Accessibility: ERPNext facilitates easy access to data from anywhere with an internet connection, promoting flexibility and remote work capabilities.
4. Document storage and retrieval: ERPNext centralizes digital storage with advanced search and retrieval functions, making it quicker and more efficient to find specific documents.
5. Security: ERPNext offers secure user authentication, encryption, and backup features, enhancing data security.
6. Costs: ERPNext leads to cost savings over time through increased efficiency and reduced errors. (Initial investment in software implementation has to be taken care of)
7. Scalability: ERPNext is easily scalable to accommodate growing data and transaction volumes without significant physical infrastructure changes.
8. Integration with other systems: ERPNext enables seamless integration with other business systems, promoting data consistency and eliminating redundancies.
9. Reporting and analytics: ERPNext provides automated reporting and analytics tools, offering insights into customer behaviour, inventory management, and other critical aspects of the business.
10. Compliance and audit trail: ERPNext offers features for automated compliance tracking and generates detailed audit trails, facilitating regulatory compliance and accountability.

Cube Doors were impressed with the presentation. They understood that ERPNext offers numerous advantages over manual paperwork, including improved accuracy, efficiency, security, and scalability to enhance overall business operations and support better decision-making through data analytics.

Custom solutioning

Wahni then confronted a significant challenge due to the varied nature of customer requirements and the distinctive specifications for each product ordered, particularly in the realm of diverse door attributes. The impracticality of pre-designing item creation became apparent when dealing with orders comprising a multitude of models, sizes, designs, patterns, frames, and colours, leading to the necessity of creating a substantial number of unique items.

To address the complexity of pre-creating over 50k+ options, Wahni implemented a straightforward solution. Basic details from incoming orders for a customer were entered and saved, generating a custom file in the backend. Upon incorporating custom measurements, automatic updates occurred for everything from the surface area of each door to the quantity of raw materials required for construction. Traditional methods of calculating overall door manufacturing based on total quantity faced challenges due to variations in purchase quantity and total surface area in each order. This new system adapted by automatically calculating raw material requirements through area-based calculations for each sales order, enhanced efficiency with the implementation of ERPNext.

The result

The integration of the ERPNext system at Cube Doors provided each franchisee direct access to the software, enabling them to input orders and other requirements seamlessly. Consequently, the head office gained real-time insights into daily orders and requirements across franchises. This streamlined document processing for production, allowing for individual attention to specific areas and customer requirements by assigning unique barcodes to each order. This approach minimized communication errors, ensured meticulous management from packing to delivery, and facilitated a better understanding of production quality and raw material consumption.

In summary, these advancements have enabled Cube Doors to conduct accurate production planning, simplify order management, expedite the production process, achieve efficient on-time delivery, accommodate more orders, and enhance overall business performance. Since the implementation of ERPNext supported by Wahni at Cube Doors, their vision to revolutionize the door industry by combining the strength of traditional materials with the versatility and durability of fibre-reinforced plastics took another turn. Cube Doors' dedicated research and development for years is now pushing them as pioneers in crafting doors that stand the test of time, embracing modern design aesthetics. Their unwavering commitment to quality is now meeting the quantity as ERPNext has now become the spinal cord of their business.