Software Development in the Indian Plastics Manufacturing Sector

Industry overview

India’s plastics manufacturing sector is a critical component of the broader industrial landscape, contributing over ₹3 lakh crore annually to the economy and employing more than 4 million people. Yet many mid-sized manufacturers in the space still rely on manual processes or outdated software to manage procurement, production, inventory & delivery, leading to inefficiencies, waste & missed opportunities for scaling. This case study details how a mid-sized plastics injection molding company in Gujarat partnered with a software development team to build a custom ERP and production planning system. The results included a 25% improvement in production scheduling efficiency, a 30% reduction in stockouts, & measurable ROI within 10 months.

Challenges Faced

The GujPlast had been operating for over a decade using a mix of Excel sheets, Tally for accounting, & standalone third-party software for basic inventory management. As the company scaled operations, multiple operational inefficiencies emerged:
● Unpredictable stockouts: Frequent raw material shortages disrupted the production
● Manual production scheduling: The floor supervisors used whiteboards and verbal communication for planning shifts.
● Zero traceability: An inability to trace defective batches back to specific machines or shifts.
● Lack of real-time reporting: Some delays in production and sales data prevented timely decision-making.
● Duplicate data entry: High overhead due to entering the same data in multiple disconnected systems.

Solution: A Custom ERP with Integrated Production Planning Module

Key Objectives:

1. 1. Automate and streamline production scheduling.

1. 1. Integrate inventory management with demand forecasting.

1. 1. Provide real-time dashboards and KPI monitoring.

1. 1. Replace manual processes with digital workflows across departments.

1. 1. Enable batch traceability and compliance-ready reporting.

Tech Stack & Architecture

● Frontend: ReactJS
● Backend: Node.js with Express
● Database: PostgreSQL, MongoDB
● Middleware/API Layer: GraphQL for data queries across modules
● Deployment: AWS EC2+RDS with S3 for document storage
● Mobile App: Flutter-based floor assistant app for supervisors

Core Modules Developed

• • Inventory Management System

• • Real-time stock updates using barcode scans

• • Auto alerts for minimum order quantities

• • Supplier rating based on delivery timelines

• • Production Planning & Scheduler

• • AI-assisted shift planner based on historic job times

• • Machine-wise Gantt chart view

• • Dynamic reallocation based on breakdowns or absenteeism

• • Quality Control Module

• • Inline quality checks are integrated via tablets on the floor

• • Automated defect classification

• • Nonconformance reports linked to production batches

• • Sales & Dispatch Tracking

• • Order entry with priority tagging

• • Dispatch scheduler with route optimization

• • GST-compliant invoicing

• • Reporting & Dashboards

• • Department-wise dashboards

• • KPIs like OEE , downtime analysis & rejection rates

• • Predictive analytics for raw material planning

Implementation Process

Phase 1: Discovery & Mapping (Month 1)

● Conducted process mapping across 5 departments.
● Identified 78 manual workflows and redundancies.
● Interviewed 23 key personnel for pain points and ideal workflows.

Phase 2: MVP Development (Months 2 to 4)

● Built 3 core modules: Inventory, Scheduler & QC.
● Piloted on 3 machines and 1 product line.
● Feedback loop every week with production leads.

Phase 3: Full Rollout (Months 5 to 7)

● Complete rollout to all 12 machines and 3 lines.
● Staff training workshops in Gujarati and Hindi.
● Real-time mobile notifications are integrated with shift supervisor phones.

Phase 4: Optimization & Reporting (Months 8 to 10)

● Fine-tuned demand forecasting algorithm using 2 years of sales data.
● Integrated vendor delivery history into reorder logic.
● Custom dashboards for the CEO and the production manager

Staff Adoption & Cultural Impact

● 82% of shop floor staff reported the mobile app improved their workflow.
● The company introduced a “Digital Shift Lead” recognition award.
● Internal promotions included roles like “ERP Champion” and “Data Accuracy Officer.”
● Monthly review meetings are now dashboard-led rather than Excel-based.

Lessons Learned

1. 1. Start small, scale fast: Piloting the MVP on a limited line helped iron out issues before a full rollout

1. 1. Language localization matters: Adding Gujarati support to the mobile UI drastically improved adoption.

1. 1. Train the trainer works: Empowering mid-level managers to train juniors increased confidence and reduced dependency.

1. 1. Executive dashboards created ownership: Leadership engagement went up when they saw live data in real time

Next Steps

● Integrate IoT sensors for real-time machine data.
● Add a predictive maintenance module based on vibration and temperature logs.
● Connect ERP with the CRM system for seamless order lifecycle management.
● Build a vendor portal for direct PO management and invoicing.

Summary

This case study demonstrates how custom software development, tailored to specific operational needs, can transform a traditional plastics manufacturing business into a data-driven, scalable operation. The improvements in production planning, inventory control, and workforce empowerment led to measurable bottom-line impact and faster decision-making.

With India aiming to become a global manufacturing hub, such technology-driven initiatives are no longer optional; they are essential