Managing a complex manufacturing operation requires complete structural visibility, especially when your daily production demands tracking exact raw copper consumption across fixed material sizes. For Pogliano Busbar, operating within the Umm Al Quwain Free Zone, a lack of unified systems threatened to slow down their rapid growth. Faced with steep legacy ERP software costs that were burning holes in their pockets, they needed an agile, cost-effective alternative to run their manufacturing, engineering workflows, and large-scale workforce. They partnered with Wahni IT Solutions to dismantle their operational silos and build a unified, high-octane open-source backbone powered by ERPNext.
Challenges
- Automated systems were entirely missing to track distinct daily copper consumption across 10 fixed sizes, making material planning highly labor-intensive.
- Critical difficulties in monitoring step by step progress from raw layout estimations and Bill of Quantities to execution left management blind to project milestones.
- Procuring raw materials lacked alignment with specific project lifecycles and tracking item warranties by serial numbers remained completely manual.
- Manually managing complex shift scheduling, localized payroll processing, and attendance data for 61 employees led to major administrative inefficiencies.
Benefits
- The newly configured system automatically converts Sales Orders into Material Requests and triggers supplier orders the moment stock drops below a set level.
- Items are tracked with pinpoint precision down to the exact room, row, shelf, and bin using serial or batch numbers alongside automated stock aging reports.
- A centralized General Ledger tailored to UAE compliance completely automates landed cost distribution and post dated cheque tracking.
- Shifts, biometric attendance, and payroll are unified into one smooth workflow alongside automated asset lifecycle and maintenance tracking.
Impact
- Tightly integrating sales with procurement ensures field engineers never wait for parts to significantly speed up project delivery times.
- Management swapped guesswork for complete clarity by instantly auditing live inventory and operations across all locations via a single dashboard.
- Linking shipping fees and asset depreciation directly to cost centers allows the finance team to see true gross profit margins at a glance.
- Moving core users from paper to a standardized platform has created a highly scalable digital launchpad for regional expansion.
Testimonial
Deploying ERPNext with Wahni IT Solutions has completely streamlined our entire operation. They successfully brought our manufacturing tracking, raw copper consumption, and multi module workflows into a single, real-time dashboard. We have eliminated guesswork, cut down
administrative overhead, and highly recommend their implementation expertise
— Mr. Anoop, CE “
