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 Yet many mid sized manufacturers in the space still rely on manual processes or outdated software to manage procurement, production, inventory & delivery, leading to inefficiencies, waste & missed opportunities for scaling.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: A 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. Automate and streamline production scheduling.
2. Integrate inventory management with demand forecasting.
3. Provide real time dashboards and KPI monitoring.
4. Replace manual processes with digital workflows across departments.
5. 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
• Non conformance 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. Start small, scale fast: Piloting the MVP on a limited line helped iron out issues before a full rollout
2. Language localization matters: Adding Gujarati support to the mobile UI drastically improved adoption.
3. Train the trainer works: Empowering mid level managers to train juniors increased confidence and reduced dependency.
4. 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