Does This Sound Familiar?
Every one of these is a solvable process and technology problem — not a “we need more staff” problem. These are the challenges our manufacturing clients face before working with us:
Production Data Lives in Registers, WhatsApp Groups, and Excel — Never in One Place
Your production counts are noted on paper registers at the end of each shift. The supervisor compiles them into Excel in the morning. The plant head sees yesterday's numbers at 11 AM. By then, a machine that ran slow during the night shift has already caused 4 more hours of lost output. Decision-making runs on stale data because your shop floor and your ERP don't talk to each other.
Your ERP Shows 'In Stock' — The Shop Floor Says Otherwise
The ERP says 500 units of finished goods are available. The warehouse actually has 480 because 20 were rejected by QC and the rejection wasn't entered. Production planning schedules the next batch based on 500. A customer orders 100. You can ship 80. Every time this happens, you lose credibility with a customer — and they remember.
Machine Downtime Is Discovered Hours After It Happens — Not in Real Time
A critical machine stops at 2 AM. The night shift operator tries to fix it for an hour, then calls the supervisor at 3 AM. The maintenance team arrives at 7 AM. The machine was down for 5 hours before anyone with authority to fix it even knew. No alert. No escalation. No real-time visibility. Every hour of unplanned downtime costs ₹50,000-₹2,00,000 depending on the machine.
Multi-Location Plants Operate in Silos — Zero Cross-Plant Visibility
Your Plant A has excess inventory of a raw material. Plant B is about to stop production because they're waiting for the same material — and they ordered it externally at a premium. Neither plant manager can see the other's inventory. Intercompany stock transfers require 3 phone calls, 2 emails, and a manual journal entry that takes 2 days to process.
Product Costing Is Done Manually at Month-End Instead of Tracked Live
Your finance team spends the first 10 days of every month calculating what each product actually cost to produce — raw materials, labor, machine hours, overhead allocation. By the time they have the numbers, the month is one-third over and any cost overruns from last month are already repeating this month. You're driving by looking in the rearview mirror.
We don't just install an ERP. We connect your physical shop floor to your digital systems — machines, sensors, production lines, QC stations — so your ERP reflects what's actually happening, in real time. Production counts auto-post. Downtime triggers instant alerts. Inventory updates automatically. Multi-plant visibility is native. And your product costs are calculated live, not reconstructed at month-end.
What We Deliver for Manufacturing
Detailed breakdown of what you get, how we do it, and what the result looks like.
Unified ERP Backbone — Business Central or ERPNext
Production orders, BOMs, inventory, and finance in one system — no more juggling three tools that don't talk to each other
We implement BC or ERPNext as your single source of truth — configured for your specific manufacturing workflows: discrete, process, or mixed-mode. BOMs, routings, production orders, material consumption, output posting — all in one place.
What You Get
Real Scenario
A 3-entity manufacturing group had production planning on Excel, inventory in Tally, and financials in a separate system. Monthly reconciliation took 10 days. We implemented BC27 with full manufacturing, inventory, and finance modules. Production data now flows from work order creation to finished goods posting to COGS automatically. Month-end close: 3 days.
Shop-Floor-to-ERP Data Bridge — IoT & Sensor Integration
Machine sensors feed real production data directly into your ERP — no human data entry, no delays, no errors
We design and deploy IoT sensors (or integrate with your existing PLCs/SCADA) that capture machine uptime, cycle counts, rejections, temperature, and energy consumption — and push this data directly into your ERP production orders and dashboards in real time.
What You Get
Real Scenario
A textile manufacturer with 40 weaving looms (most 15-20 years old) had zero digital output. We deployed retrofit vibration sensors that detect run/stop status and count cycles — no electrical connection needed. Data transmits via WiFi to a central gateway and into their ERP. Management now sees real-time loom utilization, shift-wise production, and instant downtime alerts. Production visibility went from 'paper register, next morning' to 'dashboard, right now.'
Production Planning & Scheduling Automation
Scheduling logic that reacts to material availability, machine capacity, and order priority automatically
We build custom scheduling engines (AL extensions for BC or Frappe apps for ERPNext) that optimize production sequences based on your actual constraints — machine capacity, material availability, tooling requirements, changeover times, and delivery deadlines.
What You Get
Real Scenario
An auto components manufacturer was doing production scheduling on a whiteboard — 200+ SKUs, 15 machines, constantly changing priorities. Rush orders from major customers would derail the entire week's plan. We built a scheduling engine in BC that considers machine capacity, tooling availability, and material stock. When a rush order is entered, the system shows exactly which existing orders will be delayed — before the change is committed. Planner dependency on spreadsheets: eliminated.
Multi-Location & Intercompany Automation
For manufacturers with multiple plants or group companies — automated intercompany transactions and consolidated reporting
We've built production-proven intercompany automation for multi-entity manufacturing groups. Your Plant A and Plant B can see each other's inventory, transfer stock with automated accounting entries, and consolidate financials — with a full audit trail on every transaction.
What You Get
Real Scenario
A manufacturing group with 3 entities was doing intercompany reconciliation manually — 3 days every month, with frequent errors. We built a BC27 AL extension that automates cross-company data serialization, approval routing, and event-driven posting. What took 3 days now takes 20 minutes — with zero reconciliation errors and a full audit trail.
Why Choose Dhaara Over a Regular ERP Vendor
What Our Clients Typically Achieve
Reduction in manual reconciliation time between shop floor and ERP — data flows automatically, not through registers and Excel
Month-end closing accelerated — when production, inventory, and finance data are unified, closing that took 10 days takes 1-2
Reduction in unplanned downtime through early-warning vibration and temperature alerts on aging equipment
Cross-plant inventory visibility within weeks of go-live — no more calling the branch to check stock
Frequently Asked Questions
Quick answers to common questions.
Ready to Transform Your Manufacturing Operations?
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