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The plant lost UAH 1.1 M every month due to frozen inventory and manual planning

1. Issue

Company: 85 employees, 60 door models, 220 orders/month.

Issues:

  • 12–18 h frozen stock;
  • 2-day planning cycle;
  • UAH 1.1 M monthly over-consumption;
  • cost known after 7 days.
2. Actions

  • Odoo 16 CE, 4 months, UAH 1.3 M (hardware + custom modules);

  • 28 scanners, 380 BOMs, 6 custom apps;
  • Excel eliminated.
3. Result

  • downtime ↓ 8 % → 0.9 %;

  • scheduling 35 min;
  • over-consumption ↓ UAH 0.82 M/month;
  • cost calculated in 12 min, accuracy ±1 %;
  • inventory turnover ↑ 5.4 → 8.7;
  • payback 9 months.

The plant locked up 20 % of working capital in unfinished goods because Excel/1C silos and manual planning blocked real-time visibility

1. Issue

Company: 100–150 employees, industrial metal fabrication, B2B, make-to-order & batch production.

Issues:

  • 20 % of assets tied up in unfinished goods;
  • 2–3 days per week of manual scheduling;
  • 15–25 % excess raw-material stock;
  • data scattered across Excel, 1C, paper—single view took hours/days.
2. Actions

  • Odoo 16 CE, 5 months, € 27 k (MRP, Inventory, Purchase, Quality + scales/counters);

  • 30 h training, 50+ staff;
  • Excel & paper logs eliminated.
3. Result

  • unfinished goods ↓ 20 % → 8 %;

  • scheduling 35 min;
  • raw-stock ↓ 20 % of working capital;
  • downtime ↓, output ↑ 10–15 %;
  • unit cost ↓ 7 %;
  • live data in 5 min instead of days.

The company’s lab, stuck with Excel and paper, needed 36 h to spot contamination—idling the line and burning ₴1.2 m on scrapping one batch

1. Issue

Company: 120 employees, food-additive manufacturing, B2B, batch and make-to-order, 500 kg per batch.

Issues:

  • quality control was kept in four Excel workbooks plus paper forms; 
  • a Salmonella contamination stopped production for 36 h, forced scrapping of 9 t of product and cost ₴1.2 m in losses;
  •  line downtime ran ₴28 k per hour; 
  • compliance certificates took up to two days to locate.
2. Actions

  • Odoo 17 Community, 8 weeks, ₴0.62 m;

  • Quality module + custom lab screens;
  • REST integration with lab analyzers;
  • QR-code thermal printers on every drum, Zebra mobile scanners;
  • 18 h training for 32 lab techs, QC managers and warehouse staff;
  • Excel and paper logs switched off.
3. Result

  • sample registration ↓ 4 min;

  • deviation detection ↓ 36 h → 45 min, auto line-stop;
  • spoiled-batch scrapping ↓ 9 t → 0.6 t;
  • downtime savings ₴1.9 m/year;
  • certificate retrieval via QR — 8 sec;
  • EU shipments ↑ 18 %.

The firm lost up to 4 days waiting for parts and saw 6 % of repairs come back under warranty because service history vanished in paper folders

1. Issue

Company: 90 employees, industrial pump & gearbox repair centre, B2B, 120 orders per month.

Issues:

  • 3–4 day stand-stills while waiting for spare parts;
  • repair history in paper folders, 25 min search;
  • 6 % warranty returns due to lost service data.
2. Actions

  • Odoo 17 Community, 5 weeks, € 9.5 k;

  • Inventory, Repair, Maintenance modules;
  • QR tag on every unit, mobile scanners;
  • auto-pick spare parts from stock, job list on phone;
  • 12 h training for 24 technicians & logisticians.
3. Result

  • downtime for missing parts ↓ 3 days → 5 h;

  • repair history lookup ↓ 25 min → 30 sec;
  • warranty returns ↓ 6 % → 1.2 %;
  • inventory turnover ↑ 4.1 → 6.3;
  • project payback — 7 months.

The plant lost 14 % of output from mixed raw-material lots and couldn’t tell customers where their orders were

1. Issue

Company: 110 employees, cardboard packaging manufacturer, B2B, 200,000 m² per month.

Issues:

  • 14 % waste from mixed raw-material lots;
  • manual roll count took 2 hours per shift;
  • order status was invisible to everyone.
2. Actions

  • Odoo 17 Community, 6 weeks, €0.51 m;

  • – MRP, Inventory, Barcode modules;
  • – scanner on every trolley, auto-weighing of rolls;
  • – real-time glue-line monitoring, auto-stop if moisture deviates;
  • – 15 h training for 40 operators and logisticians.
3. Result

  • waste ↓ 14 % → 2.1 %;

  • shift inventory ↓ 2 h → 7 min;
  • phone clarifications ↓ 30 → 3 per day;
  • on-time order fulfilment ↑ 82 % → 97 %;
  • payback — 9 months.