Manufacturing Operations Demo

From raw intake to dispatch — fully automated

Watch how a mid-sized Mumbai manufacturer replaced spreadsheet chaos with one unified Zoho ecosystem. 5 steps, manual vs automated.

~150 employees ₹20Cr+ revenue Precision components Production planning Zoho Creator
Step 1 of 5 20%
1
2
3
4
5
1
Raw Material Intake
Supplier order → warehouse team notification
Manual Process
🔧
Before
1
Supplier sends order confirmation via email
2
Procurement team manually logs into Excel sheet
3
Updates Google Sheets tracker
4
Notifies warehouse team via WhatsApp
5
Warehouse checks backlog — delays common
Total time 15+ min per intake
PCW Automation
⚡
Automated
✓
Supplier email auto-parsed — PO number, SKU, quantity extracted
✓
Zoho Creator intake form auto-populated
✓
Inventory levels updated in real time
✓
Warehouse team gets Slack notification instantly
✓
Stock discrepancy flagged before goods arrive
Total time 8 seconds
Zoho Creator — Material Intake Form
Auto-filled from supplier email · 8 seconds after receipt
PO Number
PO-2026-0847
Supplier
Precision Alloys Ltd · Mumbai
Material Grade
SS 304 — 2mm sheets
Qty Received
200 sheets
Bin Location
WH-A · Rack 14
Expected Delivery
Today by 3:00 PM IST
SS 304 Precision Alloys WH-A Auto-parsed PO-2026-0847
✓
Slack notification sent to #warehouse-ops
200× SS 304 sheets incoming · Bin WH-A pre-allocated · Team notified — no manual WhatsApp needed
2
Production Scheduling
Daily job allocation across machines and operators
Manual Process
🔧
Before
1
Operations manager reviews Excel sheet every morning
2
Manually assigns jobs to machines based on availability
3
Checks raw material stock per job
4
Prints schedule and posts on shop floor board
5
Reschedules when anything changes — twice daily minimum
Manager time per day 45 min+
PCW Automation
⚡
Automated
✓
Zoho Creator auto-generates daily job schedule overnight
✓
Factors in: order priority, machine capacity, operator shifts
✓
Cross-checks raw material availability per job
✓
Shop floor sees live dashboard on tablet — no paper
✓
Reschedules automatically on material delay or machine downtime
Manager time per day < 5 min
Zoho Creator — Production Schedule · Today
Live dashboard · Auto-generated at 6:00 AM · 26 May 2026
7:00 AM
BATCH-1047
Laser Cut #1 · Rahul K.
9:30 AM
BATCH-1049
Welding Station · Suresh P.
12:00 PM
BATCH-1051
CNC Mill #2 · Amit J.
3:00 PM
BATCH-1052
Assembly · Pending material
✓
Schedule Auto-Generated — 4 jobs queued
Jobs scheduled
4
Machine utilisation
94%
Blocked jobs
1
Manager review
< 2 min
3
Quality Check
QC data captured in real time, pass/fail routing automated
Manual Process
🔧
Before
1
QC engineer fills paper checklist after each batch
2
Manually enters pass/fail into a separate Excel sheet
3
Quality supervisor reviews at end of day
4
Failed batches issued via email to operations
5
Compliance report compiled manually at month-end
End-of-day review 60+ min
PCW Automation
⚡
Automated
✓
Zoho Creator mobile form captures QC data in real time
✓
Auto-routes failed batches for re-inspection immediately
✓
Live dashboard shows: reject rate, cycle time, first-pass yield
✓
Slack alert fires for supervisor on any fail
✓
Compliance report auto-generated weekly — no manual work
End-of-day review < 2 min
Zoho Creator — QC Dashboard · Live KPIs
97.2%
First-Pass Yield
2.4%
Reject Rate
18 min
Avg Cycle Time
⚠
Alert — BATCH-1051 · CNC Mill #2
Tolerance deviation
+0.3mm over spec
Action triggered
Auto-re-inspection queued
Supervisor notified
Via Slack · 3 min ago
Batch status
Under review
4
Inventory Management
Real-time stock sync, auto-alerts, one-click reconciliation
Manual Process
🔧
Before
1
Monthly physical stock count — 2 days of operations shutdown
2
Manager manually reconciles against purchase orders
3
Discrepancies resolved via WhatsApp threads
4
Updated Excel shared with finance — version mismatches common
5
Finance reviews old data — current stock unknown until next count
Month-end close 2–3 days
PCW Automation
⚡
Automated
✓
Real-time sync across Zoho Inventory + Books
✓
Auto-alerts when stock falls below reorder level
✓
Auto-match with purchase orders and invoices
✓
One-click reconciliation report for finance — any time
✓
Finance always sees real-time stock — no monthly surprise
Month-end close Instant
Zoho Inventory — Stock Levels · Live
MaterialOn HandReorder AtStatusLast Movement
SS 304 Sheets — 2mm 340 sheets 200 ✓ In Stock Today 8:42 AM
Aluminium Bar — 25mm 89 units 100 ⚠ Low 23 May 2026
Brass Fittings — 12mm 23 units 50 🔴 Critical 20 May 2026
Copper Wire — 3mm 1,240 m 500 ✓ In Stock Today 9:15 AM
⚠
2 items below reorder level — PO auto-drafted for Brass Fittings
Aluminium Bar: 89/100 · Brass Fittings: 23/50 · Finance notified · Purchase order pending your approval
5
Dispatch & Reporting
Shipment tracking, invoice auto-creation, Friday management report
Manual Process
🔧
Before
1
Logistics team shares tracking via email after dispatch
2
Operations manually updates dispatch Excel
3
Finance chases invoice status via WhatsApp threads
4
Customer waits for invoice — 2–5 day delays common
5
Management report compiled manually every Friday
End-of-week reporting 4–6 hours
PCW Automation
⚡
Automated
✓
Zoho Inventory auto-generates dispatch record on shipment
✓
Invoice auto-created on delivery confirmation
✓
Customer receives invoice automatically — no manual chase
✓
Zoho Reports dashboard shows: orders fulfilled, dispatch delays, revenue per SKU
✓
Management report auto-sent Friday 8:00 AM
End-of-week reporting Zero manual time
Zoho Reports — Operations Dashboard · 26 May 2026
47
dispatches completed this week
94.2%
On-time rate
2
Delay incidents
₹18.4L
This week revenue
4.1x
Inventory turns
📊
Management report scheduled — Friday 8:00 AM
Weekly ops digest auto-sent to 4 stakeholders · Orders fulfilled, delay rate, revenue per SKU, inventory turns · No manual compilation needed
🔧
Tools
Email + WhatsApp + Excel
⚡
Tools
1 unified Zoho ecosystem
⏱
Ops team time
4–6 hrs/day manual
⚡
Ops team time
30 min/day review
📄
Reporting
Weekly manual compile
⚡
Reporting
Live dashboards