Skip to main content

Transforming Valve Manufacturing with Sigzen’s ERP Solution

October 08, 2025
ERP for valve manufacturing

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.

Heavy dependence on manual processes slowed down critical operations like quotation preparation, stock adjustments, and production planning.

Fragmented systems created data silos, making it difficult to track inventory, monitor order statuses, and measure production progress in real-time.

Documentation errors frequently occurred in sales orders, purchase orders, and invoices due to the lack of automation.

Approval workflows were inefficient, leading to delays in stock movement, order fulfillment, and sales processing.

Compliance challenges emerged, particularly in subcontracting workflows and GST reporting, due to the absence of a robust ERP system.

Large and unstructured product database with 87,000+ SKUs had no standardized item codes or valuation methods, leading to pricing inaccuracies and inconsistencies in reporting.

Inability to automate communications like sales summaries, stock reorders, and approval triggers caused recurring delays and missed deadlines.

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

1. Item Master Overhaul

check-icon
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.

2. Advanced Warehouse Management:

check-icon
Centralized warehouse mapping for multiple locations.

Improved raw material and finished goods traceability across the supply chain.

3. DocType Enhancements

check-icon
Customized Quotation, Sales Order, Packing Slip, Production Plan, and Shipment workflows to fit the specific needs of valve manufacturing.

4. BOM-driven Quotation Automation

check-icon
Automated retrieval of BOM cost values for accurate quotations.

Eliminated pricing errors and improved client trust.

5. Auto-Packing Slip Creation

check-icon
Packing slips automatically generated at Delivery Note submission, cutting down manual work from 15 minutes to under 1 minute.

6. Production Plan Optimization

check-icon
Raw material availability checks before creating work orders reduced last-minute procurement issues.

7. Automation & Scheduling

check-icon
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.

check-icon
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.
check-icon
KPIs Improved
  • Order fulfillment cycle time reduced from 6 days to 2 days.
  • Zero missed reorder notifications post-automation.
check-icon
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.
Rating: 5 / 5 (1 votes)
Close Menu