Pharma Distribution ERP
A batch-driven ERP for a distributor handling 4,000+ SKUs across three godowns, replacing four disconnected systems.
View case studyManufacturing · Brass & Metal Industry
Brass Manufacturing ERP
Weight-based ERP with job work reconciliation and scrap recovery accounting for a brass components unit.
- Client
- Brass components manufacturer, Jamnagar
- Industry
- Brass & Metal Industry
- Duration
- 4 months
- Platform
- Web + Android
About the Project
The client manufactures brass components with a substantial part of the process outsourced to local job workers for turning, plating and polishing. Their existing software counted pieces; their business ran on kilograms. The mismatch meant material reconciliation was done on paper and never quite balanced.
The Challenge
Between material issued to job workers and finished parts received, roughly 4–6% of weight went unaccounted for. Nobody could say how much was legitimate process loss, how much was unrecorded scrap, and how much was simply not coming back. Material outstanding with job workers had no ageing visibility, so some had been sitting for over a year.
Job costing used the previous month's brass rate, which meant quotations lagged behind a volatile metal market.
Our Solution
We built the entire inventory model around weight, with piece counts as a secondary measure. Every job work issue and receipt is reconciled: finished weight plus recovered scrap plus recorded loss must account for what went out, with the variance shown per worker and per process.
Scrap is booked back against the originating job and valued at the current rate, so job costing reflects true recovery. Costing pulls the metal rate at the moment of issue rather than a monthly average.
An ageing report on outstanding job work material now drives a weekly follow-up routine.
The Result
Unaccounted material loss dropped from roughly 5% to under 1.5% within four months — mostly because the variance became visible per worker and could be discussed with specific evidence. Around ₹18 lakh of material outstanding with job workers for more than six months was recovered in the first quarter.
Quotations now reflect the current metal rate, protecting margin when brass prices move sharply.
Measured Impact
- 5% → 1.5%
- Unaccounted material loss
- ₹18L
- Aged material recovered
- 30+
- Job workers tracked
- Live
- Metal-rate costing
Key Features Delivered
- Weight-based inventory with grade and section tracking
- Job work issue and receipt reconciliation per worker
- Scrap recovery booked against the originating job
- Material ageing with job workers
- Rate-at-issue job costing
- Process-wise rejection analysis
- Machine-wise production capture
- Dispatch and packing list generation
“Every software company we spoke to wanted to count pieces. Our business runs on kilograms and job work, and SOLVENEST were the only ones who understood that without us having to explain it three times. We recovered material that had been sitting with job workers for over a year — that recovery alone covered the project cost.”
More Work
Related Case Studies
Sales CRM for Industrial Equipment
A CRM handling nine-month sales cycles, multi-stage quotations and a field team across four states.
View case studyB2B Dealer Ordering Portal
A self-service ordering portal for 350 dealers, with tiered pricing, credit limits and live ERP stock.
View case studyFree consultation
Have a Software Requirement? Let's Discuss Your Idea.
Tell us about your business challenge and our team will help you identify the right technology solution — no obligation, no sales pressure.
- Response within one business day
- NDA on request
- Fixed-scope or retainer engagement