Customer Story · DL Valve
Sigzen ERP: Precision Manufacturing for the Valve Industry
Client Profile
Company Name : DL Valve Industry: Industrial Manufacturing – Valve Production Business Size: Medium-sized, 250+ employees, multiple manufacturing sites
Brief Overview The client is a prominent manufacturer specializing in high-precision industrial valves, with large-scale procurement, production, and supply chain operations serving both domestic and export markets.
Challenges Faced Before ERP Implementation
Before adopting Sigzen’s custom ERP solution built on ERPNext, DL Valve struggled with multiple operational inefficiencies across sales, inventory, production planning, and compliance.
Item & Warehouse Management Issues
No consistent item coding system for 87,000+ SKUs. Lack of proper valuation methods created pricing errors and unreliable financial reporting. Difficulty in locating stock across multiple warehouses delayed operations. No clear raw material visibility caused frequent last-minute procurement and production delays.
Manual Operational Bottlenecks
Quotation preparation was completely manual, with no BOM-driven cost automation, causing pricing errors. Packing slips had to be created manually after each delivery, consuming significant time. Sales Order and Production Plan workflows required excessive human intervention. Stock transfers and adjustments were inconsistent, creating discrepancies in inventory. Approvals and communication flows were slow and prone to errors.
Business Impact of Challenges
Higher turnaround times for customer orders. Increased procurement delays due to poor visibility of raw material stock. Increased labor costs and administrative strain. Reduced client confidence due to inaccurate pricing and frequent documentation errors.
Solution Offered by Sigzen
To address these challenges, Sigzen deployed DL Valve ERP, a tailored ERPNext implementation designed specifically for the valve manufacturing industry. The solution automated workflows, standardized product management, and optimized production planning. ERP Platform Deployment of Sigzen’s custom ERP for manufacturing built on ERPNext, enabling scalable, industry-specific operations.
Key Modules & Customization
Item Master Overhaul
Designed a standardized item coding system for 87,000+ products. Implemented structured product categorization and assigned accurate valuation methods. Enhanced inventory visibility with real-time ERPNext item master management.
Advanced Warehouse Management:
Centralized warehouse mapping for multiple locations. Improved raw material and finished goods traceability across the supply chain.
DocType Enhancements
Customized Quotation, Sales Order, Packing Slip, Production Plan, and Shipment workflows to fit the specific needs of valve manufacturing.
BOM-driven Quotation Automation
Automated retrieval of BOM cost values for accurate quotations. Eliminated pricing errors and improved client trust.
Auto-Packing Slip Creation
Packing slips automatically generated at Delivery Note submission, cutting down manual work from 15 minutes to under 1 minute.
Production Plan Optimization
Raw material availability checks before creating work orders reduced last-minute procurement issues.
Automation & Scheduling
Sales summary emails, reorder triggers, and approval workflows fully automated. Standardized notifications improved communication across teams.
Implementation Process
Rollout Strategy
Rollout Strategy Phase 1: Item master restructuring & valuation setup. Phase 2: Sales and quotation automation. Phase 3: Production, warehouse, and shipping workflow digitization.
Collaboration
Conducted workshops with inventory control, production, and finance teams to ensure alignment. Adopted iterative testing phases to minimize disruptions.
Training & Support
Staff were trained to use new quotation automation, warehouse workflows, and ERP document handling. Post-go-live support provided through a dedicated ERPNext support team to ensure smooth transition.
Results and Business Impact
After implementing Sigzen’s ERP for valve manufacturing , DL Valve witnessed measurable improvements across operations.
Measurable Improvements
100% of 87,000+ SKUs standardized with proper item codes and valuation. 60% reduction in sales and stock entry processing times. 80% decrease in manual documentation errors. 60% faster quotation preparation using BOM-driven automation. Packing slip creation reduced from 15 minutes per order to under 1 minute.
KPIs Improved
Order fulfillment cycle time reduced from 6 days to 2 days. Zero missed reorder notifications post-automation.
Qualitative Benefits
Consistent and structured product data improved decision-making. Easier onboarding for staff managing sales and inventory. Improved client trust due to pricing accuracy and timely delivery. Enhanced scalability with flexible ERPNext customization tailored to valve manufacturing needs.