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Also serving Madras
A Chennai plant that passes every customer audit can still lose money between purchase and dispatch; process optimisation finds where, before any ERP is configured.
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Photo: SlowPhoton · CC BY-SA 4.0, cropped · via Wikimedia Commons
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Buyers order when stores shout, with no link to the customer schedule
A planning rhythm with reorder rules and approval limits
One trusted manager approves everything, until the day he leaves
Written authority limits, maker-checker steps and exception reports
A confused process put into software, confusion at higher speed
Ownership and rules settled before configuration starts
Chennai's manufacturers are well audited. Customer audits, quality-system audits and statutory audits come round every year, and the certificates hang in reception. Yet the same plants carry excess stock, expedite freight every week and discover margin problems at year end. Audits check whether the written procedure is followed, not whether it is sensible.
Business process optimisation and control design is the work we do before, or apart from, an ERP project. We walk each process from trigger to cash, document how it really runs, identify the delays, duplicate entries and missing controls, and design the future process with clear ownership and approval limits. The output is process maps, control matrices and SOPs that any ERP team can configure from.
Case studies
Indus Motor Company Private Limited
Indus Motor — ERPNext Cut Stock-Outs 40% Across Showrooms
Kerala State Road Transport Corporation (KSRTC)
KSRTC — ERPNext Courier System Delivered ₹1 Crore in Profit
Dumas Bakes N Meals Private Limited
Dumas Bakes N Meals — ERPNext Lifted On-Time Deliveries by Over 40%
An example
Tuesday begins at the gate of a plastics moulding unit in Ekkattuthangal, where our consultant watches a granule delivery arrive and notes who signs what. She follows the material to stores, then to the machine, then follows a finished lot back to packing and the dispatch bay, asking at each step who decides, who records and what happens when something is short. By noon she has found that rejects are weighed but never costed, that mould changes are planned on a whiteboard the buyer never sees, and that two people can each change a customer's rate. In the afternoon she sits with the owner, the supervisor and the accountant and draws the process as it really runs.
This is the one service where we spend most of the engagement on site. Our consultants come to Chennai for process walks and interviews from the gate to the accounts desk. Documentation and design are done in Kochi, then we return to present the future-state design to your management and refine it with the people who will run it.
Assessment. Interviews, document reviews and live mapping of how work really runs.
Redesign. Streamlined processes, approval levels, responsibilities and measures.
Control design. Approvals, audit trails and access rules that fit how you work.
SOPs and documentation. Step-by-step procedures that double as an onboarding handbook.
ERP alignment. Process maps and priorities your ERP can be configured from.
The scope and timeline are agreed in writing before work starts.
Automotive & auto components
Order-to-dispatch mapping against customer schedules, job-work and returnable-packaging controls, rejection and rework accounting, and premium-freight analysis, for suppliers who must show process discipline to vehicle makers.
Electronics manufacturing
Component stores control for high-value, small-size parts, engineering-change handling so the floor builds to the right revision, consigned-material accounting, and scrap and yield reporting both finance and production accept.
Ports & logistics
Job-opening to invoicing flow for forwarders and CFS operators, control over unbilled jobs and vendor accruals, credit approval for customers, and documentation checkpoints that prevent demurrage and detention disputes at the ports.
An audit looks backward and reports gaps against the existing procedure. Our work looks forward and redesigns the procedure itself, then writes it in a form an ERP can be configured from.
No. The blueprint belongs to you and is written to be independent of the software. Many clients do continue with us into ERPNext implementation, but you are free to take it to any vendor.
They accept it when they have shaped it. We design with the supervisors and clerks who do the work, show them what gets easier, and keep the owner's decisions visible. Resistance usually comes from changes imposed without explanation.
After a first conversation about the departments involved, how many processes and what prompted the review, we agree the scope and send you a written quotation. The price, the deliverables and the timeline are fixed against that scope before any work starts, so nothing grows without your sign-off.
You speak to someone who does this work, not a call centre. They ask about which departments and processes are involved and what is going wrong. If it looks like a fit, we agree the scope and put it in writing, with the timeline, before any work starts. If it does not, we tell you.
Engineering cluster, Ekkattuthangal-Ambatturcluster
Soft-intervention cluster (2008-09) covering engineering units in Ekkattuthangal and Ambattur; a common facility centre for the Ambattur engineering cluster is also listed under MSE-CDP.
A soft-intervention MSE-CDP cluster with a common facility centre. Its units serve vehicle makers who audit process discipline, so a documented, sensible procedure is a commercial asset here.
Source: dcmsme.gov.inPlastics cluster, Guindy-Ekkattuthangal-Ambatturcluster
Plastic-processing units spread across the three estates, taken up as an MSE-CDP soft-intervention cluster in 2008-09.
Plastic-processing units spread across three estates. Granule purchase, mould changes and reject costing are the three processes where a walk usually finds the leak.
Source: dcmsme.gov.inSIDCO Electrical and Electronics Estate, Thiruvanmiyurpark
A SIDCO electrical-and-electronics estate in south Chennai, administered from the Guindy branch.
A SIDCO estate in south Chennai whose electronics units hold small, high-value components. Stores control and engineering-change handling are the controls that matter most here.
Source: tansidco.orgPlaces and organisations are named for local context only. Acube Innovations is not affiliated with or endorsed by them.
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Kochi (Kadavanthra & Infopark) · Thiruvananthapuram · across India & overseas · In business since 2011