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Odoo ERP system improves the efficiency of manufacturing process management for Varroc in India

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Client

Varroc Group is a leading global automotive component manufacturer

Founded in 1988 in India, today Varroc Group is an award-winning Tier 1 global automotive manufacture and supplier specialising in exterior lighting systems, plastic and polymer, electrical-electronics and precision metallic components to passenger car and commercial vehicles worldwide. The company has 41 world-class manufacturing facilities and 16 engineering centres ​in 14 countries.

Background and challenge

The IT system that Varroc used before did not have enough functionality, it was not scalable, and delayed the work of more than 150 employees

How it worked before

Before Notamedia started to work on the project, Varroc team had been using an IT-system developed by another provider.

The task to be solved

Varroc was looking for a tailor-made tool to automate manufacturing processes end-to-end, as well as to integrate and manage other software solutions they have been using at their distributed production sites.

Why it stopped working

Over time it has become difficult to manage multiple phases of Varroc’s manufacturing processes by using this software. The IT-system has not been updated since 2016 and it lacked functionality.

Chosen solution

We offered two fitting solutions, and Varroc approved Odoo software. It is one of the fast-growing ERP solutions in the market, with top-notch usability and functionality that scales across all apps, and it doesn’t require license fees.

Development process

Automation process has covered almost all the most important areas of the enterprise's life: production process management, sales, finance, personnel, and logistics

Requirements gathering and system design

Varroc needed the following ERP modules: production processes management system, purchasing, accounting, CRM, HR management, tasks management, WMS, and TMS — all with high-level data protection. The ability to augment the system with other modules in the future was also significant. We have developed a system prototype that has clearly displayed the company's processes and designed user interfaces.

Development and implementation

Odoo ERP is a well-structured open-coded software system using technologies like Python, JavaScript, HTML5, CSS, and PostgreSQL database. It includes an extensive set of modules that can be supplemented and customized to all individual needs. The centerpiece of that stage was a fine-tuned customization of Odoo's modules in order to perfect-fit the needs and peculiarities of Varroc's enterprises. We also provided a seamless Odoo integration with other IT systems operated by Varroc to manage them effectively.

Testing and QA

In order to ensure that the system guarantees trouble-free operation and matches the requirements, we have provided a series of testing. In addition to standard workload testing, system testing was performed by our analytics team. They checked user experience, as well as the stability and security of the system. A UAT (User Acceptance Testing) was then initiated involving the customers — it’s a stage where we were able to check the entire flow and confirm that all customizations are in place as per the requirements specified.

The challenge

Processes in Varroc have a pronounced specificity, which should be taken into account and clearly reflected in each module of the ERP system. In-depth interviews with the processes owners, description of each process, and accurate prototyping of it helped us to implement flexible ERP solution in a short time.

Outcome

We have developed a scalable tool for managing key processes and IT systems of Varroс with fine-tuned customization to the company's specifics

Today, the ERP system is used by Varroc to manage numerous business processes and IT systems in the Electrical Parts division. The tool allows the department to monitor purchases, sales, production, staff work, finance, and logistics easily and efficiently. In particular, managers can see at what stage of the production process there was a delay: when setting a task, at the stage of purchasing, manufacturing or delivery.
Financial flow management allows finding opportunities to reduce costs and determining future investments. It is expected that the use of the system will be expanded to cover the needs of all Varroc's divisions and enterprises around the world.
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