Managing electronics manufacturing involves more than assembling products. Businesses need a clear view of production planning, material consumption, inventory movements, and finished goods.
For Micron EMS Tech Pvt. Ltd., manufacturing activities and inventory records were previously managed through manual processes and spreadsheets. This made it difficult to track production progress, maintain customer-wise inventory records, and ensure consistency in item master data.
Indictrans implemented ERPNext to establish a structured manufacturing workflow, improve inventory traceability, and introduce custom validation to prevent duplicate item creation.
About Micron EMS Tech Pvt. Ltd.
Founded in 2011 and headquartered in Bengaluru, India, Micron EMS Tech Pvt. Ltd. is an Electronics Manufacturing Services (EMS) provider serving customers across multiple industries worldwide.
The company specializes in PCB assembly and electronic product manufacturing, with a focus on quality, reliability, and precision. It continues to invest in Surface Mount Technology (SMT), modern manufacturing practices, and collaborative engineering support to deliver manufacturing solutions for diverse customer requirements.
Business Challenges
1. Unstructured Manufacturing Process
- Manufacturing activities were not managed through a centralized ERP system.
- Production planning was handled manually without a systematic workflow.
- Sales Orders, Production Plans, Work Orders, and Finished Goods were not properly linked.
- Material consumption was recorded manually, resulting in inaccurate inventory records.
- Production progress could not be tracked in real time.
- There was no standard process for work order creation, job card management, or production completion.
2. Manual Client-wise Inventory Management
- Client-owned inventory was maintained manually in Excel.
- Inventory was maintained with zero valuation, making financial tracking challenging.
- Material movement between warehouses was not captured systematically.
- Identifying available stock for individual customers was difficult.
- There was no proper audit trail for inventory movement.
3. Inventory Traceability Issues
- Material receipts, transfers, and consumption were recorded manually.
- Tracing which raw materials were consumed for specific production orders was difficult.
- Limited visibility into stock availability resulted in planning delays.
4. Manual Approval Process
- Business approvals were managed through emails and verbal communication.
- There was no workflow-based approval mechanism.
- Document approvals were delayed.
- Approval history and accountability were limited.
5. Duplicate Item Creation
- Users frequently created duplicate Item Masters.
- Similar items existed under different item codes.
- Duplicate records increased the complexity of inventory management.
- Procurement planning and reporting became more difficult.
Our Approach
1. Implemented an End-to-End Manufacturing Process
One of the primary objectives of the ERP implementation was to establish a structured and standardized manufacturing process for Micron EMS Tech Pvt. Ltd.
Before implementation, the team managed production activities manually, which limited visibility into production planning, material consumption, and work-in-progress.
To address these challenges, we implemented the ERPNext Manufacturing Module and designed an end-to-end manufacturing workflow covering Sales Orders, Production Planning, Material Requirement Planning (MRP), Work Orders, Bills of Materials (BOMs), Routing, Workstations, Job Cards, Material Transfers, Material Consumption, Manufacturing Stock Entries, and Quality Inspection.
This enabled production tracking from raw material issuance to finished goods receipt.
The implementation replaced manual production tracking with a centralized, ERP-driven process, providing real-time production visibility, improving inventory traceability, enhancing production planning, and standardizing manufacturing operations across the organization.
Key Benefits
- Standardized the end-to-end manufacturing process.
- Improved production planning and scheduling.
- Enabled complete material and production traceability.
- Reduced manual effort and operational errors.
- Enhanced inventory accuracy and real-time production visibility.
- Improved coordination between Production, Stores, and Quality teams.
2. Structured Client-wise Inventory Management
Before ERP implementation, the team maintained client-wise inventory manually in Excel and assigned it zero valuation. This made it difficult to track stock movements, reconcile inventory, and maintain accurate records.
There was no standardized process to monitor customer-owned inventory or ensure complete traceability.
To address these challenges, we designed and implemented a structured client-wise inventory management process in ERPNext using Stock Entries.
The solution enabled the systematic recording of Material Receipts, Material Transfers, Material Consumption, and Finished Goods movements. This improved the visibility and traceability of customer inventory while maintaining the required zero valuation.
3. Implemented Inventory Traceability
We implemented a structured approach to improve visibility into inventory movements.
Implemented
- Material Receipt Entries
- Material Transfer Entries
- Material Consumption Entries
- Manufacturing Entries
- Warehouse-to-Warehouse Transfers
- Finished Goods Entries
Benefits
- Complete audit trail.
- Easier inventory reconciliation.
- Real-time stock availability.
- Customer-wise inventory visibility.
4. Custom Solution for Duplicate Item Prevention
Micron EMS frequently faced issues with duplicate Item Master records, resulting in inconsistent inventory data, procurement challenges, and reporting inaccuracies.
Since the business follows different identification criteria for raw materials and finished goods, standard ERPNext validation was not sufficient to meet its requirements.
To address this, we designed and implemented a custom validation mechanism based on Item Groups. The system automatically validates item details during Item creation and prevents duplicate records according to predefined business rules.
Raw Materials
For raw materials, the system validates the combination of Item Name, Make, and Manufacturing Part Number.
The system allows users to create a new item only when at least one of these values differs. If all three values match an existing item, the system displays an “Item Already Exists” error and prevents duplicate creation.
Finished Goods
For Finished Goods, validation is based solely on the Item Name. If an item with the same name already exists, the system blocks the creation of a duplicate record.
Key Benefits
- Prevented duplicate Item Master creation.
- Standardised Item Master management based on Item Groups.
- Improved inventory data accuracy and consistency.
- Reduced procurement and inventory management errors.
- Simplified reporting and master data maintenance.
- Ensured compliance with the client’s business rules for Raw Materials and Finished Goods.
ERPNext can also help manage other manufacturing operations, including procurement planning. For example, Weyeah Power in China uses a Purchase Planner workflow to align purchase orders with supplier capacity and organize incoming deliveries.
Modules Implemented
Core Modules
- Manufacturing
- Inventory
- Buying
- Selling
- Stock
- Quality Inspection
Outcomes and Impact
Manufacturing
- Standardised the complete manufacturing lifecycle.
- Improved production planning accuracy.
- Enabled real-time production tracking.
- Improved material utilisation.
- Reduced manual production activities.
Inventory
- Implemented structured inventory movement.
- Achieved customer-wise inventory visibility.
- Established complete stock traceability.
- Eliminated manual inventory registers.
- Improved inventory accuracy.
Master Data
- Prevented duplicate Item Master creation.
- Improved Item Master quality.
- Reduced procurement errors.
- Improved reporting and analytics.
Workflow Automation
- Faster approval cycle.
- Automated notifications.
- Increased process transparency.
- Better compliance and audit readiness.
Operational Benefits
- Reduced manual effort across departments.
- Improved inter-departmental coordination.
- Supported better decision-making through real-time ERP data.
- Increased operational efficiency.
- Standardized business processes across manufacturing and inventory.
Conclusion
For electronics manufacturers, reliable production planning depends on having clear records of materials, production activities, and inventory movements.
With ERPNext, Micron EMS established a structured manufacturing workflow, improved client-wise inventory traceability, and introduced custom validation to prevent duplicate item creation.
The implementation brought key manufacturing and inventory processes into a centralized system, giving teams a more consistent way to manage production activities and maintain operational records.
Looking to structure your manufacturing operations with ERPNext? Indictrans can help you connect production planning, inventory, and quality processes around your business requirements.
