Short Answer: WoodCraft Industries, a Selangor furniture manufacturer with 85 employees, reduced production time by 45% after implementing Odoo MRP — eliminating 4 hours of daily manual work orders and cutting material shortages from 30% to under 5%.
Table of Contents
- Company Profile
- The Challenge
- The Odoo MRP Solution
- Step-by-Step: Implementation
- Frequently Asked Questions
- Results & Metrics
- Pros
- Cons Encountered
- Summary
Company Profile
| Detail | Info |
|---|---|
| Company | WoodCraft Industries |
| Location | Shah Alam, Selangor |
| Industry | Furniture Manufacturing |
| Employees | 85 |
| Revenue | RM12 million/year |
| ERP Partner | Systum360 |
The Challenge
WoodCraft Industries was drowning in manual processes. Production planners spent 4 hours daily creating work orders on paper. Material shortages caused 30% of orders to be delayed. Quality issues were discovered only at final inspection, leading to 15% rework rates.
Key Pain Points
- 4 hours/day on manual work orders
- 30% order delays from material shortages
- 15% rework rate from late quality checks
- No visibility into production status
- RM180,000/year in wasted materials
The Odoo MRP Solution
The team rolled out Odoo Manufacturing with MRP (Material Requirements Planning) to automate production planning, material procurement, and quality control.
Modules Implemented
- Manufacturing — Work orders, BOM, routing
- Inventory — Real-time stock tracking, reorder rules
- Purchase — Automated procurement from suppliers
- Quality — In-process quality checks
Step-by-Step: Implementation
- Week 1–2: Process mapping and BOM creation for top 20 products
- Week 3–4: Inventory setup with reorder rules for 500+ raw materials
- Week 5–6: Work order automation and routing configuration
- Week 7–8: Quality checkpoints at each production stage
- Week 9–10: Staff training and parallel run
- Week 11–12: Go-live and optimization
Frequently Asked Questions
How long did the Odoo MRP implementation take?
12 weeks from kickoff to go-live. This included process mapping, data migration, configuration, training, and a 2-week parallel run.
What was the ROI timeline?
WoodCraft achieved positive ROI within 4 months. The 45% reduction in production time and elimination of material waste saved RM180,000 in the first year.
Did employees resist the change?
Initially, yes. Production planners were used to paper-based work orders. Systum360 provided hands-on training and a 2-week parallel run to build confidence.
Can Odoo MRP handle custom furniture orders?
Yes. Odoo supports configurable BOMs (Bill of Materials) for custom orders. Each custom piece gets its own work order with specific materials and routing.
Results & Metrics
| Metric | Before | After | Improvement |
|---|---|---|---|
| Production time | 100% | 55% | 45% reduction |
| Material shortages | 30% of orders | Under 5% | 83% reduction |
| Rework rate | 15% | 3% | 80% reduction |
| Daily manual work | 4 hours | 30 minutes | 87% reduction |
| Annual material waste | RM180,000 | RM25,000 | RM155,000 saved |
Pros
- ✅ 45% faster production — automated work orders eliminate bottlenecks
- ✅ Real-time visibility — managers see production status on dashboards
- ✅ Quality built-in — checks at every stage, not just final inspection
- ✅ Cost savings — RM155,000/year in reduced material waste
Cons Encountered
- ⚠️ Initial resistance — production staff preferred paper work orders
- ⚠️ Data migration — BOM creation for 500+ products took 2 weeks
- ⚠️ Custom routing — some unique processes needed custom configuration
Summary
WoodCraft Industries transformed their manufacturing operations with Odoo MRP, achieving 45% faster production, 83% fewer material shortages, and RM155,000 in annual savings. Contact Systum360 to learn how MRP can transform your manufacturing business.
📞 Contact us: +6011 5995 0954 | tech@systum360.com | www.systum360.com