Proof from the shop floor

ERP Implementation Stories: Five Real Projects from the Shop Floor

Every factory runs differently. These are five systems Tejaxo has configured or built for manufacturers – a CNC and VMC machining plant in Faridabad, a metal strip processor, a rubber moulding plant, a calibration-services business and a multi-plant group. Each story shows the problem, the workflow step by step, real screens with all names and values blurred, and what changed.

The five projects

At a glance

#	Industry	Problem	What Tejaxo delivered
1	CNC / VMC machining, Faridabad	Are there enough machines and shifts for this month?	Machine-capacity planning from work orders and cycle times
2	Metal strip processing	No coil-level history; quality checked only at the end	Barcode per coil, tablet scanning, stage-wise quality, coil history
3	Rubber moulding	Wrong or expired compound reaching the machine	QR app: scan-matched issue, QA by scan, expiry control, 13 reports
4	Calibration services	Bookings and status chased by phone	Customer app: booking, quote, stage tracking, invoices, live van
5	Multi-plant group	Plant reports late and in different formats	One-screen MIS: growth patterns, plant / state / customer drill-down

Story 1 · CNC / VMC machining · Faridabad

CNC and VMC machining plant, Faridabad: monthly machine capacity planning

A precision machining plant in Faridabad replaced its capacity spreadsheet with a machine-capacity module inside Tejaxo ERP that turns the month’s work orders and part cycle times into machines required per machine type.

At a glance

Industry	Precision machining (CNC, VMC and other machine types)
Location	Faridabad, Haryana
System	Tejaxo ERP - production planning and control (PPC): plant capacity planning
Documents	Machine Master PPC · Capacity Machine Master · Product Machine Linking (one-time) · Production Work Order (daily) · Process Plant Capacity (monthly) → Machine Summary
Users	Production planning (PPC) and plant management
Status	Live (in use at the plant)

The challenge

Every month the planning team had to answer one question before committing to delivery dates: do we have enough CNC and VMC machines and shifts for this month’s orders? The answer lived in a spreadsheet that had to be rebuilt by hand from orders, stock and cycle times, so it was always late and never matched the live work orders.

What changed

The capacity spreadsheet was retired: the same formula now runs row by row inside the ERP, on live work orders.
Planning sees, before the month starts, which machine type needs an extra shift, overtime or outside capacity.
Parts that cannot be planned (no machine link) are visible at once instead of being discovered on the shop floor.

How it works, step by step

Machine master for planning. Every machine is recorded with an automatic machine code, its section and costing fields: running cost, overhead cost, operators and helpers.
Capacity groups. Up to 20 machine types (for example CNC, VMC and others) are defined, and each machine is linked to its group. The planning grid takes its column headings from these group names.
Cycle time per part. For every part, the cycle time in seconds per piece is entered once for each machine type it runs on.
Demand from work orders. “Get Month Data” pulls every production work order dated in the selected month, deducts finished-goods stock already made against those orders, and allows add / less corrections to give the revised net production.
The calculation. Machines required = revised net production × cycle seconds ÷ (seconds per hour × efficiency × working days × hours per day). Efficiency, working days and hours per day have defaults and can be changed on each line.
Machine summary. For every machine type the plant sees load hours, machines required, machines available, shortfall (+) or spare (−), and load %.
Controls. Parts with no machine link are flagged, one name is enforced per code, negative cycle times are rejected, and everything recalculates on save.

Screens from the project

Tejaxo ERP process plant capacity machine summary screen — Machine summary: load hours, machines required against machines available, shortfall or spare, and load % for each machine type

Tejaxo ERP process plant capacity month data screen — Process plant capacity: month, efficiency, working days and hours per day, then "Get Month Data" pulls demand from work orders

Tejaxo ERP item machine requirement grid in the plant capacity screen — Item machine requirement: net production converted into required CNC, VMC and other machine hours for every part

Tejaxo ERP product machine linking with cycle time per part — Product machine linking: cycle time in seconds per piece for each part on each machine type

Tejaxo ERP capacity machine master screen — Capacity machine master: every machine linked to a capacity group such as CNC or VMC

Real screens from the project. Company, product and party names and all values are blurred. Click a screen to enlarge.

Who this suits

Machine shops, auto-component suppliers and engineering plants where the bottleneck is machine hours, not material: CNC turning, VMC, grinding, gear cutting and press shops.

Manufacturing ERP in Faridabad · Machine capacity planning · CNC machine data and OEE · Production planning and MRP

Story 2 · Metal strip processing

Metal strip processor: coil-wise traceability from casting to finished product

A metal strip processing plant runs its whole line in Tejaxo ERP coil by coil: a barcode on every coil, tablet scanning at each stage, quality recorded after every step, and the complete history of any coil on one screen.