Back to Case StudiesManufacturing & Power pH Meters • Case Study
Toshcon: Replacing Excel Spreadsheets with a Smart Manufacturing ERP
Client
Toshcon
Industry
Manufacturing & Power pH Meters
Solution
Zoho Manufacturing ERP
Partner
AvolveLabs
How Toshcon digitized production tracking, inventory, quality control, and workforce productivity.
The Challenge
Managing multi-level Bills of Materials (BOMs), work orders, raw material consumption, and shop-floor productivity across separate Excel spreadsheets led to operational bottlenecks. Management lacked real-time visibility into shop-floor progress, inventory levels, and production stage delays, making reporting slow and reactive.
The Transformation
AvolveLabs designed a custom, connected Zoho Manufacturing ERP layer built on Zoho Creator, Inventory, Books, and Analytics:
- Centralized BOM & Product Masters: Replaced version-controlled spreadsheets with systematically tracked multi-level BOMs and revision histories.
- Digital Shop Floor & Job Cards: Digitized work orders and assigned daily tasks directly to work centers and individual operators via digital job cards.
- Embedded Quality Control (QC): Integrated mandatory QC inspection checklists at every phase—Incoming, In-Process, and Final Dispatch—linking non-conformance records directly to work orders.
- Connected Vendor Portal: Automated RFQs, PO approvals, and vendor communication through a dedicated digital portal.
- Shop-Floor Productivity Analytics: Linked operator activity with biometric attendance to generate real-time worker KPI scorecards and shift productivity reports.
Sales Order ➔ Multi-Level BOM ➔ Purchase Order ➔ Production & Job Card ➔ Integrated QC ➔ Dispatch
The Impact
- Single Source of Truth: Eliminated reliance on disconnected Excel sheets across production, inventory, and procurement.
- Real-Time Shop Floor Visibility: Enabled live tracking of work-in-progress (WIP) status, machine usage, and stage bottlenecks.
- Scrap & Waste Optimization: Created direct traceability between raw material consumption, defect tracking, and financial reporting.
“Moving from Excel to a connected Zoho ERP gave Toshcon total control over shop-floor operations, material flow, and worker efficiency.”
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