Case Study: ERP Implementation for Rupali Group
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Case Study: ERP Implementation for Rupali Group
Industry: Marker Paper & Printing | Modules: Accounting, HR & Payroll, LC Management, Fixed Assets and Production.
Background
Rupali Group, a growing marker paper and printing manufacturer, faced major operational challenges due to manual processes and lack of real-time visibility. Their accounting, production, inventory, and import operations were all running on spreadsheets or standalone tools, resulting in inefficiencies, delays, and errors.
To overcome these challenges, Rupali Group collaborated with Infoex Bangladesh Ltd. To implement a complete ERP solution tailored for manufacturing operations.
Key Challenges before ERP implementation
Manufacturing & Production Challenges
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Raw materials were consumed higher than the actual requirement, but no system existed to compare usage vs. job order.
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Could not track job order–wise production, leading to planning and costing issues.
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No standard Bill of Materials (BOM) was maintained.
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Inspection rejects had no tracking, causing invisible production loss.
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Difficulty identifying top-selling items, top customers, and sales trends.
Inventory & Stock Issues
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No proper tracking of stock aging (old vs. new stock).
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Warehouse location tracking was not available.
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Real-time stock reports could not be generated, causing delays in production planning.
Accounting & Financial Limitations
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Customer credit limit and credit days could not be controlled.
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Import/LC-related extra charges, such as freight, duty, and handling cost, were not tracked efficiently.
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No accurate visibility of: Profit/Loss, Expense monitoring, Audit trail and Cost centers.
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Monthly closing took a long time due to fully manual documentation.
ERP Solution Delivered
Manufacturing Management
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Job order–wise production tracking with complete material consumption reports.
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Standard BOM creation and automatic material requirement planning.
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Reject/inspection tracking to identify production loss.
Auto-generated reports for
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Top-selling items
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Top customers
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Item-wise cost
Inventory & Store
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Real-time stock visibility with warehouse location mapping.
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Stock aging report for better planning.
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Automated GRN, material issue, consumption, and closing stock reports.
General Ledger.
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Accounts Payable.
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Accounts Receivable.
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Cash & Bank.
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Cost Center.
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Supplier outstanding
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Daily cash statement
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Production cost
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Item-wise profitability
More importantly:
Customer credit limit and credit days (automation implemented).
LC Management module added
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Imported item costing.
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Extra charges allocation.
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Duty, freight, C&F, transport, and other overheads.
Fixed Assets module implemented with depreciation tracking.
All payroll calculations automated (OT, leave, deduction, allowances).
Salary & attendance reports generated automatically.
Custom Features Developed
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LC Management.
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Fixed Assets Tracking.
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Job Order–wise Production Monitoring.
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Implementation Timeline & Training.
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Total Implementation Duration: 1.5 months.
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Training Provided To: Accountant, Sales Team, IT Manager, AGM, DGM, MD, QC Manager, Operators, and all related staff.
Results after ERP Implementation
Manufacturing & Inventory Improvement drastically.
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Material consumption accuracy improved significantly due to BOM and usage tracking.
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Production planning became faster and more data-driven.
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Reject/inspection visibility helped reduce hidden production loss.
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Real-time top-selling item and customer analytics improved sales strategy.
Accounting & Financial Outcomes
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Monthly closing time reduced drastically (from several days to just hours).
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100% accurate customer credit control.
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Import costing became transparent and accurate.
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Audit and cost center visibility improved across departments.
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Finance reporting speed increased by more than 70%.
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Payroll accuracy increased by 80%.
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Monthly payroll processing time reduced significantly.
Conclusion:
By implementing a fully integrated ERP solution, Rupali Group transformed their manufacturing, accounting, and operational processes. The company now enjoys real-time visibility, accurate costing, improved financial control, and efficient production management—helping them scale confidently for future growth.