Overview

A well-established wire and cable manufacturer specializing in custom cable sheathing using extrusion lines set out to enhance their production transparency and quality assurance. Their process included complex multi-level BOMs, in-house compounding, and continuous extrusion runs that demanded precision and consistency. However, manual record-keeping and fragmented tools were slowing production, allowing defects to go unnoticed, and disrupting material planning. Ksolves implemented a tailored Odoo ERP solution that unified production, quality control, procurement planning, and real-time monitoring, streamlining operations from raw materials to finished cable reels.

Manufacturing

Industry

Odoo ERP

Technology

100%

Success Rate

Braincuber

Partner

Challenges

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• Complex Multi-Level BOMs: Products involved deeply nested BOMs that created difficulties in accurate costing, production scheduling, and change tracking.
✗
Missing Batch Traceability: Quality results were not digitally tied to specific batches or extrusion runs, making it difficult to trace issues back to their origin.
✗
Inadequate QC Checkpoints: Without standardized checkpoints during raw material intake or in-line extrusion, early-stage defects such as sheath irregularities or performance failures often went undetected.
✗
Unmonitored Machine Behavior: Machine anomalies during extrusion led to unplanned downtime, affecting overall throughput and consistency.
✗
Procurement Planning Issues: A disconnection between procurement, inventory, and production created challenges in the timely sourcing of critical materials, particularly specialized polymers.
✗
Limited Forecasting Visibility: Lack of historical usage insights and predictive tools led to frequent material shortages or overstock, directly impacting production flow and working capital.

Our Solution

Braincuber implemented a manufacturing-tailored Odoo ERP solution with the following enhancements:

✓
Structured Multi-Level BOM Management: Defined clear hierarchies for every product, including nested components and sub-assemblies, allowing for better planning, costing, and engineering change control.
✓
Batch QC Log Integration: Mapped each production batch to specific quality checkpoints like sheath thickness, spark resistance, and tensile strength, making quality data accessible and traceable across batches.
✓
Inward and In-Line QC Automation: Automated quality validation at material intake and during extrusion helps detect defects early, eliminates manual errors, and reduces rework.
✓
IoT-Based Machine Monitoring: Integrated sensors on extrusion lines, combined with Odoo's IoT module, enabled real-time visibility into operational performance and proactive alerts for anomalies.
✓
Integrated Procurement Planning: Connected procurement workflows with production schedules and BOMs, ensuring timely sourcing of materials and reducing the risk of stockouts or over-purchasing.
✓
Demand Forecasting and Inventory Optimization: Enabled forecasting tools that analyzed historical consumption trends to predict future material needs, supporting better inventory planning and cost control.

Results & Impact

✓

• Achieved full batch traceability, enabling faster issue identification and resolution.

✓

Reduced production defects through automated QC checkpoints during both raw material intake and in-line stages.

✓

Improved equipment uptime with real-time machine monitoring and proactive issue alerts.

✓

Enhanced material planning with integrated procurement and forecasting capabilities, reducing last-minute shortages and excess stock.

✓

Reduced material waste and rework through better control of BOM structures and quality at source.

Conclusion

By adopting Odoo ERP, the wire and cable manufacturer significantly elevated its control over quality, production efficiency, and material planning. The new system enabled end-to-end traceability, streamlined procurement, and data-driven forecasting, all integrated into a single platform tailored to the needs of modern cable manufacturing. Braincuber continues to support The company in building on this foundation, exploring opportunities such as predictive maintenance, advanced dashboarding, and expanded process automation.

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