Streamlining Supply Chain for a Heavy Machinery Manufacturer
Client Background
A heavy machinery manufacturer with three production facilities and a global supply chain struggled with inventory mismanagement and delayed deliveries. Manual processes and disconnected systems led to overstocking, production bottlenecks, and dissatisfied customers. The company sought a Zoho-based solution to optimize inventory, improve customer communication, and enhance supply chain visibility.
Challenges
- Inventory Overstocking: Lack of real-time inventory tracking caused $500,000 in excess stock annually.
- Delayed Deliveries: Manual order processing resulted in 20% of shipments missing deadlines.
- Poor Customer Communication: Inconsistent updates frustrated clients, impacting repeat business.
- Limited Visibility: Management lacked insights into supply chain performance and production status.
Solution
We implemented a tailored Zoho ecosystem to address these challenges:
- Zoho Inventory: Configured a centralized inventory system with real-time tracking across warehouses. Automated reorder points and low-stock alerts reduced overstocking. Integrated with shipping carriers (e.g., UPS, DHL) for streamlined logistics.
- Zoho CRM: Built a customer management system with custom modules for order tracking, service requests, and contract details. Automated workflows for order confirmations and delivery updates.
- Zoho Projects: Set up project templates for production cycles, with task assignments and milestones for each machinery order. Integrated with Zoho CRM to align sales and production teams.
- Zoho Analytics: Created dashboards to monitor inventory turnover, delivery performance, and customer satisfaction, accessible to executives on mobile devices.
- Security Features: Implemented role-based access and encrypted data transfers to protect sensitive client and supplier information.
Implementation Process
- Requirement Analysis: Conducted workshops with supply chain, sales, and production teams to map workflows.
- System Customization: Used Zoho Deluge to script 15+ automation rules, including reorder triggers and delivery notifications.
- Data Migration: Transferred 5,000+ product SKUs and 2,000 customer records to Zoho Inventory and CRM.
- Training: Trained 80 staff members on inventory management, CRM usage, and project tracking, with department-specific guides.
- Go-Live and Support: Rolled out the solution in phases, with 24/7 support for 60 days to ensure smooth adoption.
Results
- Reduced Overstocking: Inventory costs dropped by 30%, saving $150,000 annually.
- Improved Delivery Times: On-time deliveries increased to 95%, boosting customer satisfaction by 25%.
- Enhanced Communication: Automated updates via Zoho CRM improved client retention by 20%.
- Better Visibility: Real-time dashboards reduced decision-making time by 40%, optimizing production planning.
- Cost Efficiency: Eliminated redundant tools, saving $20,000 per year in software costs.
Client Testimonial
“The Zoho solution transformed our supply chain. We now have full control over inventory and deliveries, and our customers appreciate the timely updates. The team’s expertise ensured a flawless implementation.” – Robert Kline, Operations Director