ERP Case study.  Electrical / Electronics (Discreet Product) Manufacturing Industry 

Power Electronics Industry. Standard products (yet configurable as

per specific customer’s requirements). Case study of Erp in UPS
and Inverter manufacturing company with “After sales service
division”.

BACKGROUND:

The company is ISO 9001 certified for its quality standards and is
an exporter to many countries, including Southeast Asia, Africa, Mid
East, Eastern Asia, etc. Major Products Includes: Online UPS
Inverters up to 400 KVA. Solar/Wind Hybrid Solutions. Customized
Power Backup Solution. Emergency Lift Operating Systems.

This enterprise is a leader in making UPS and Inverters. The owner

is a very dynamic and a true entrepreneur had the vision of
becoming a global player. The management decided to deploy ERP
software for business management.

The special module that was thought of was the ‘Service module’.
This takes care of the after sales service, warranty management,
service call management, service reports, spares used in the field
for repairs, and so on. Their major customers are individual
companies, banking sector, builders, etc.

ISSUES & CHALLENGES:

Supply chain Management: • Variety of application load of the product, as well as the
changes in end user requirements is a big challenge that
Item master:
management was facing.

Cable, Fuse • With the legacy system, the Bills of Material (BOM) could
not be drilled down to the level of the material required for
Capacitor manufacturing a certain quantity. This led to higher
inventory levels. The head of production department was
PCB Assembly
planning mostly based on assumption, resulting in dead
LED, IC, Diode inventory.

Relay, Resistor • The product is sold under warranty. Now, the service
division will take care of after sales service. The challenge
Thyristor, Transistor is to give the service in quickest possible time and keep
track of the customer’s complains. Spares used under
Batteries warranty or under AMC. Spares to be billed and so on.

– Tubular/Stationary • Some production is carried out based on advance planning

and then configured as per the specification. Here number
Packing Material of batteries and battery make, technical specs are captured
and stored for proper inventory management.

• Serial number capturing and storing them in the ERP

database is important for future reference during the after
sales service.

www.dnserp.com                                             By Jyotindra Zaveri  Page 1 
 
  

ERP Case study.  Electrical / Electronics (Discreet Product) Manufacturing Industry 

HOW ERP CAN ADDRESS THESE ISSUES:

History card is linked with • ERP has given a comprehensive and integrated solution, with
work order, name of modules for, Purchase processing, sales Order Receipt
customer, and gives vital Information processing - ORI link with sales invoice, production,
information such as serial inventory management. User friendly GUI was given to prepare
number. the Bill of Materials (BOM) master. UPS Company’s internal
team was drawn from the ‘task force’, experience users and end
users. This played a crucial role in implementation of the new
system, as faster decisions making was possible. Serial number
is stored.
• With a knowledgeable and motivated ERP coordinator, internal
team and ERP implementer and programmers, the
implementation was completed successfully.
• By implementing following ERP Modules:

1. Security module 9. Production module

2. Accounts module – 10. CRM module (Customer
3. VAT / Sales Tax module relationship
4. Excise module management) and pre-
5. Inventory Management sales module.
module 11. Cost sheet module –
6. Purchase preparing estimate
7. BOM – Bill of Materials 12. Order Fulfillment module
module – Sales Accounting –
8. Subcontractor-out domestic & export
module 13. Warranty
management for the
Service Division.

KEY BENEFITS:

1. Better material management, by tightly linking the

purchase order, material inward, and material issue to
production has resulted in efficient work flow.
2. In service division the tracking of spares and parts usage
has empowered the users in this power electronics
manufacturing company.

www.dnserp.com                                             By Jyotindra Zaveri  Page 2