Transforming Manufacturing Operations at Sigma Terminal with Odoo

🏢 Client Overview

Sigma Terminal is a leading manufacturing company specializing in high-quality copper-based products, including copper wires, rods, and custom copper components used across industries such as electrical, automotive, and infrastructure. Headquartered in India, Sigma has built a reputation for delivering precision-engineered copper products that meet stringent industry standards.

With a strong emphasis on innovation, product reliability, and timely delivery, Sigma serves a wide base of both domestic and international clients. The company operates a modern manufacturing facility equipped with advanced machinery and follows strict quality control processes to ensure product consistency and customer satisfaction.

As Sigma grew, so did the complexity of its operations—ranging from raw material procurement, production scheduling, and quality inspections to managing a large inventory of finished goods. While they had adopted the Odoo Community Version 12 as their ERP platform to bring structure to their processes, the system was not optimized to match their real-world operational needs.

This gap between system capabilities and business requirements began to hinder productivity, decision-making, and inter-departmental coordination. That’s when Sigma Terminal partnered with KoderXpert Technologies LLP to rebuild and realign their Odoo ERP for enhanced efficiency and growth readiness.

❗Challenges Faced

Despite having an ERP system in place, Sigma Terminal faced several ongoing challenges:

• Production workflows were disjointed, leading to manual errors and delays.
• Inventory data was unreliable, causing overstocking, stockouts, and procurement delays.
• Quality control processes were not integrated, making it hard to trace defects or enforce batch-level quality checks.
• Reports lacked real-time accuracy, making it difficult for managers to make data-backed decisions.
• Product management was inconsistent, with poorly structured BOMs and product variants.
• The system overall was slow, cluttered, and difficult for users to navigate and trust.

🎯 Goals & Objectives

Sigma Terminal approached KoderXpert with the following goals:

• Streamline and digitize production and inventory processes.
• Integrate quality management directly into the workflow.
• Enable real-time, accurate reporting for operational insights.
• Simplify the system for everyday users to boost adoption.
• Clean and organize master data for long-term sustainability.

✅ Solution Provided by KoderXpert

KoderXpert stepped in to restructure the entire Odoo v12 Community setup, customizing it to truly reflect Sigma’s real-world manufacturing operations. This included:

• Rebuilding production workflows to support multi-level routing, work centers, and material consumption tracking.
• Developing a custom quality module embedded in production and purchase flows.
• Configuring and customizing inventory to enable automatic stock updates, alerts, and location tracking.
• Optimizing the product master, including BOM restructuring and variant logic.
• Custom dashboard and reports for daily production, stock movement, and performance tracking.

All changes were delivered with zero reliance on proprietary modules—fully custom-built within Odoo Community v12.

🔧 Our Implementation Process

To ensure a seamless and result-driven Odoo ERP improvement for Sigma Terminal, KoderXpert followed a structured, step-by-step approach:

1. Comprehensive System Audit

We began with a detailed audit of the existing Odoo Community v12 setup. This included:

• Reviewing configurations in production, inventory, and reporting modules.
• Identifying gaps, inconsistencies, and redundant customizations.
• Conducting interviews with key users to understand real pain points and workflow bottlenecks.

2. Requirement Mapping & Blueprinting

Once we identified the issues, we collaborated with Sigma’s management and functional teams to:

• Document their actual business processes.
• Define clear goals for each module (e.g., accuracy in stock levels, real-time reporting, etc.).
• Create a functional blueprint aligning their business flow with Odoo capabilities.

3. Custom Development & Reengineering

Based on the blueprint, we restructured the existing system by:

• Customizing production workflows to reflect real-time operations from raw material issuance to finished product delivery.
• Building new quality checkpoints within production and receiving processes.
• Redesigning the product master, BOM, and variant structures for simplicity and accuracy.
• Developing tailor-made reports for operations, daily output, and stock status.

4. Data Cleanup & Migration

We cleaned and corrected existing master data (products, routings, BOMs, stock levels) to remove duplicates and inconsistencies.

• Mapped and migrated corrected data into the restructured modules.
• Ensured legacy data from previous transactions was traceable and not lost.

5. User Testing & Feedback

We deployed the system in a controlled environment and invited department heads and end-users to:

• Test all workflows in real-time.
• Validate accuracy and ease of use.
• Share feedback, which we used to make quick iterations.

6. Training & Go-Live

To ensure smooth adoption:

• We conducted hands-on training sessions for all functional departments.
• Shared user manuals for future reference.
• Offered go-live support to assist users during the transition week.

7. Post-Go-Live Support & Optimization

After implementation:

• We closely monitored system performance and user experience.
• Addressed minor issues in real-time.
• Optimized report load times, inventory reconciliation, and dashboard visibility based on user behavior and management inputs.

🚀 Key Features Delivered

KoderXpert delivered a fully tailored Odoo ERP solution that addressed Sigma Terminal's specific operational challenges. Each feature was designed to enhance visibility, efficiency, and accuracy across departments.

✅ 1. Customized Production Workflow

We developed a detailed production flow within Odoo that mirrored Sigma’s actual shop-floor process:

• Multi-step routing with proper work center tracking.
• Real-time tracking of raw material consumption and WIP (Work In Progress).
• Automated generation of manufacturing orders based on sales demand or reorder rules.
• Batch and lot tracking integrated into each production stage.

This gave production managers complete control over scheduling, progress tracking, and bottleneck identification.

✅ 2. Inventory Synchronization & Reorder Alerts

The inventory module was redesigned for real-time accuracy and smart planning:

• Automated stock movements across warehouses and production zones.
• Reorder rules and minimum stock levels configured for each product category.
• Barcode integration support for faster picking and stock adjustments.
• Real-time inventory dashboards with accurate product availability data.

This drastically reduced manual inventory adjustments and stockouts.

✅ 3. Integrated Quality Control

We embedded quality checks directly within the production and procurement processes:

• QC checks were auto-triggered at defined stages (e.g., after production, before delivery).
• Configurable quality control parameters per product or batch.
• Pass/fail recording with reason tracking and photo attachments.
• Quality alerts with corrective action recommendations.

This helped Sigma ensure consistent product quality and reduced customer complaints.

✅ 4. Advanced, Real-Time Reporting

We built custom reports and dashboards to deliver clear insights for decision-making:

• Daily production summary reports by shift, product, and work center.
• Inventory aging reports to monitor slow-moving stock.
• Procurement lead time and supplier performance analysis.
• Delivery and sales reports with profit margin tracking.

All reports were integrated with filters for flexible, role-based access and real-time updates.

✅ 5. Simplified Product & BOM Management

To reduce errors and streamline manufacturing, we redesigned product and BOM management:

• Uniform naming conventions and product coding structures.
• Parent-child BOM support with accurate consumption rates.
• Multi-variant support with simplified product creation logic.
• Version control for BOM and routing changes.

This reduced duplicate products and made master data far easier to manage and train on.

✅ 6. User-Friendly Dashboards & Interface Enhancements

We ensured that users—from the shop floor to top management—had a smooth experience:

• Clean, intuitive dashboards for each department (Production, Inventory, Quality, etc.).
• Role-based access control to minimize clutter and increase focus.
• Quick links and shortcuts to frequently used actions.
• Light custom theming and layout optimization for usability.

This improved adoption rates and reduced dependency on the IT team for everyday tasks.

📊 Results & Impact

The transformation of Sigma Terminal’s ERP environment through KoderXpert’s expertise delivered significant operational improvements and measurable business outcomes:

⏱️ 40% Faster Production Cycle

By eliminating manual interventions, automating material consumption tracking, and streamlining production routing:

• Manufacturing processes became faster and more predictable.
• Real-time visibility into production stages helped supervisors make quick decisions and reduce delays.
• Downtime between production stages was minimized through better coordination between work centers.

📉 Significant Reduction in Stock Mismatches and Errors

Inventory accuracy was one of the most noticeable improvements:

• Automated stock adjustments and warehouse movements reduced dependency on manual entry.
• Cleaned and structured product data eliminated duplicate entries and confusion.
• Physical stock count discrepancies dropped significantly, improving procurement and production planning.

📊 Real-Time Access to Reports for Better Decision-Making

Customized dashboards and automated reporting enabled data-driven management:

• Department heads could now monitor daily output, material consumption, and delivery status in real time.
• Accurate stock and performance reports enabled faster procurement, sales, and production decisions.
• Reports previously generated manually over hours were now available with a single click.

🔄 Automated Quality Checks Reduced Rework

With quality control integrated into production and purchase flows:

• Inspections became a routine, standardized part of operations.
• Defects were caught earlier in the process, reducing the volume of rejected or reworked products.
• Sigma's commitment to product quality was reinforced without adding extra effort or headcount.

🙌 Higher User Adoption Across Departments

Thanks to improved usability and proper training:

• Employees felt more confident using the system, resulting in wider adoption.
• Role-based dashboards simplified navigation and focused each user on relevant tasks.
• Reduced reliance on IT or supervisors for everyday actions like generating reports or managing stock.

💬Client Testimonial

“We were struggling with an ERP system that looked good on paper but wasn’t helping us in practice. KoderXpert came in, understood our business, and rebuilt everything the way it should’ve been from the beginning. Today, we have a powerful system that works for us, not against us.”

— Operations Head, Sigma Terminal

🔚 Conclusion

The successful transformation of Sigma Terminal’s ERP system is a testament to the power of aligning technology with real-world business needs. What started as a fragmented and underutilized Odoo setup was turned into a robust, intuitive, and fully integrated ERP system — tailored specifically for Sigma’s copper manufacturing operations.

Through our collaborative approach, KoderXpert:

• Understood the unique workflows and challenges of the manufacturing domain.
• Applied deep functional and technical expertise to re-engineer Odoo Community v12.
• Delivered a solution that not only solved operational bottlenecks but empowered the workforce with actionable data and user-friendly tools.

The transformation didn’t just improve productivity — it brought structure, visibility, and confidence to every department, from the shop floor to the boardroom.

This project clearly reflects how we at KoderXpert Technologies LLP uphold our mission of:

Transforming Ideas into Digital Excellence.

Whether it’s reviving a misaligned ERP system or building one from scratch, our focus remains on creating solutions that drive real business value — tailored, scalable, and built to last.