Bachan Laser

Project Overview

Client: Bachan Pvt. Ltd.
Industry: Fibre Laser Cutting & Welding Machine Manufacturing
Project Type: Custom ERP Implementation
Objective: Streamline inventory, accelerate production, and gain real-time operational control

Bachan Pvt. Ltd. manufactures complex fibre laser machines consisting of hundreds of components, precision parts, and outsourced assemblies. As order volume increased, their existing manual and semi-digital processes could no longer support efficient operations.

The Problem

Inventory Bottlenecks

• Inventory was managed using spreadsheets and manual registers

• No real-time stock visibility across raw materials, bought-out parts, and assemblies

• Frequent production stoppages due to missing components

• Overstocking of slow-moving items increased working capital blockage

Slow Production Cycles

• Production planning was not linked with inventory availability

• Work-in-progress (WIP) tracking was absent

• Departments worked in silos with no centralized workflow

• Delays in one stage affected entire machine delivery timelines

Operational Risks

• No audit trail for inventory usage

• High dependency on key personnel for information

• Inaccurate production forecasting

Our Solution Provided

1. Intelligent Inventory Management System

We implemented a real-time inventory module designed specifically for machine manufacturing.

Key Capabilities:

• Live stock tracking for raw materials, components, and sub-assemblies

• Minimum stock level alerts to prevent shortages

• Consumption-based inventory deduction linked with production jobs

• Batch & serial tracking for critical laser components

Impact:

• Eliminated unexpected stock shortages

• Reduced excess inventory holding

• Improved material planning accuracy

2. Production Planning & WIP Tracking

We built a job-based production workflow that mapped each machine’s lifecycle.

Features Included:

• Job cards generated directly from confirmed sales orders

• Stage-wise production tracking (fabrication → assembly → testing → dispatch)

• Real-time WIP visibility

• Production delays identified instantly

Impact:

• Faster production cycles

• Clear accountability at each manufacturing stage

• Reduced idle time caused by missing materials

3. Management Dashboard & Reporting

A centralized dashboard gave leadership full visibility.

Dashboard Insights:

• Inventory health status

• Active production jobs

• Pending material requirements

• Delivery timelines

Result:
Management shifted from reactive firefighting to data-driven planning.

Results Achieved

• 40% reduction in production delays

• Significant reduction in inventory mismatches

• Improved machine delivery timelines

• Better coordination between inventory and production teams