Overview

A prominent solar panel manufacturer specializing in PV cell assembly and field installation needed an ERP system that could bridge manufacturing precision with installation visibility. Their operations covered wafer processing, PV cell fabrication, module assembly, logistics, and large-scale on-site installations. However, legacy systems created gaps between production and installation workflows. Warranty validation was slow due to missing genealogy data, compliance reporting was manual, and installation records were disconnected from manufacturing QC. These inefficiencies increased the risk of product recalls, warranty disputes, and costly service delays. Ksolves partnered with The company to deploy a customized Odoo ERP solution that tightly integrated manufacturing operations with installation and service management, creating a unified traceability chain from raw silicon to customer-installed solar panels.

Manufacturing

Industry

Odoo ERP

Technology

100%

Success Rate

Braincuber

Partner

Challenges

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The challenges faced by The company are as follows:
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Complex Multi-Stage Manufacturing: Solar panels required multi-level BOMs spanning wafers, PV cells, modules, and complete panels.
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Disjointed Installation Tracking: No system to link installed panel IDs with their manufacturing history.
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Warranty Verification Gaps: Claims were difficult to validate due to missing traceability between cell batches and installations.
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QC Inefficiencies: Manual inspection of cracks, soldering, and efficiency reduced throughput and caused delays.
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Compliance Burden: Renewable energy certifications and government audits required time-consuming documentation.
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Downtime Risks: Lack of IoT monitoring meant machine anomalies disrupted PV cell production without early alerts.

Our Solution

Braincuber implemented a manufacturing + installation-focused Odoo ERP solution with the following key enhancements:

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Multi-Level BOM Management: Structured wafer-to-panel BOMs to ensure accuracy in planning, costing, and assembly.
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PV Cell & Module Traceability: Created digital genealogy for every panel, linking wafers, cells, and modules through to final assembly.
✓
Installation Integration: Connected Odoo Manufacturing with the Field Service module, ensuring each installed panel ID was tied back to its production batch and QC history.
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Warranty-Linked Tracking: Automated warranty validation by mapping installation data (customer, site, panel ID) with its manufacturing genealogy.
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IoT-Driven QC: Integrated sensors for real-time monitoring of PV cell efficiency, micro-crack detection, and soldering quality.
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Field Service Management: Enabled installation teams to log tasks, issues, and inspections directly in Odoo, syncing with manufacturing data.
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Compliance & Audit Automation: Centralized documentation and audit trails to meet ISO and renewable energy certification standards.
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CAPA Workflows: Automated non-conformance handling for both production defects and field installation issues.

Results & Impact

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• Achieved high traceability from wafer to installed panel across manufacturing and field service.

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Reduced warranty claim resolution time + installation-linked validation.

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Improved panel performance with fewer defects through IoT-enabled QC.

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Increased installation efficiency with integrated scheduling and service tracking.

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Reduced downtime with real-time machine anomaly alerts in PV cell production.

Conclusion

By unifying manufacturing operations with field installation workflows, Odoo ERP provided the solar panel manufacturer with true end-to-end traceability. The integrated system streamlined production, ensured faster and more accurate warranty claims, and improved customer trust with transparent service records. Braincuber continues to enhance the system with predictive analytics, energy yield dashboards, and advanced service planning to optimize both production and installation efficiency.

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