Client Overview

The client is an electronics and IoT manufacturing company building products used in safety, automation, agriculture, and industrial monitoring. Its portfolio includes security devices, motor pump controllers, smart street light controllers, and power failure alert systems.

The product mix is wide and keeps evolving. BOMs change frequently, and even small component-level errors often surface much later, typically during testing or dispatch. While Zoho Books was already used for accounting, production data either reached it late or not at all.

Manufacturing Setup

The client operates a multi-stage electronics assembly setup consisting of:

• SMT machines

• DIP machines

• Kit issue section

• Testing stations

• Assembly, QA, and packing lines

Multiple SKUs move through the shop floor simultaneously. Stores, production, and quality teams handle the same material across different stages. Accuracy depends heavily on correct kit issuance and clean handoffs between teams.

Key Challenges Before Implementation

• No lot-wise or rack-wise traceability once material entered stores

• Manual GRN and consumption entries into Zoho caused delays and frequent mismatches

• Purchase and sales tracking lacked a fixed structure and lived across systems and spreadsheets

• BOM-based kit issuance errors were common and often detected only after assembly started

• Incoming quality checks existed but were not centrally tracked

• Serial or barcode-level traceability was missing, especially after dispatch

Explore how ManufApp’s Inventory Management enables lot-wise traceability

Solution Overview

The client implemented ManufApp with a real-time integration to Zoho Books to digitize shop-floor execution, inventory traceability, and financial sync.

The focus was on daily usability and control, not just reporting.

Key Benefits Delivered

1. Lot & Rack-Wise Material Tracking

Every inward material is now tagged with a lot number and rack location.
Stores teams can instantly see where material is stored and which lot is being issued.
Tracing issues back to the source no longer takes hours.

2. Lot-Wise Pricing & Costing

Purchase lots often arrive at different rates.
ManufApp maintains lot-level pricing so consumption reflects actual purchase cost.

This ensures:

• Correct lot pricing

• Accurate consumption costing

• Clean COGS sync into Zoho

• No month-end corrections

3. Structured Purchase & Sales Tracking

All flows now follow a fixed path:

GRN → IQC → Accepted / Rejected

Sales invoices, delivery notes, and GRNs sync automatically to Zoho.
Documentation is consistent, and vendor performance is reviewed using actual lot data.

4. IQC & Digital Inspection Tracking

Each inward batch goes through a digital inspection checklist.
Results are recorded against the lot, not on paper or loose files.

This enables:

• Standardized testing

• Clear batch-wise approvals or rejections

• Digital quality records

• Direct linkage between IQC and material availability

5. Barcode & Serial-Level Traceability

Barcodes or QR codes are generated for individual products.
Serial numbers, MAC IDs, or IMEI numbers are mapped during production.

Scanning is used during:

• Assembly

• Testing

• Dispatch

Warranty and service traceability is now possible without manual lookup.

6. BOM-Controlled Kit Issuance

Kit issuance is strictly governed by BOM.
Incorrect component issues are blocked at the stores level itself.

This reduced:

• Line stoppages

• Rework

• Mid-assembly corrections

7. Real-Time Financial Accuracy in Zoho

All material movements sync automatically, keeping Zoho aligned with shop-floor reality.

• Stock levels stay accurate

• COGS reflects actual production

• Sales values no longer require reconciliation

8. End-to-End Traceability

Each finished device can now be traced from component inward to final dispatch.
When questions arise, data is already available.

Discover how ManufApp’s Production Management supports accurate BOM-based execution

ManufApp + Zoho Integration Implementation

1. Complete Shop Floor Digitization

Production stages were connected step by step:

SMT and DIP tracking
BOM-based kit issuance
Testing and quality approvals
Assembly and final inspection
Serial, MAC, and IMEI tracking

The focus stayed on daily usage, not features.

2. Real-Time Zoho Sync

ManufApp syncs the following automatically into Zoho Books:

Item creation
GRNs and inwards
Material consumption
Production completion
Inventory adjustments
Dispatch and delivery challans

Manual accounting entries were removed instead of being monitored.

Functional Flow Diagram for Integration

Impact and Results

100% lot-level traceability across materials.
Material wastage and rework reduced.
Zero manual entries into Zoho.
Dispatch cycles became faster due to scanning.
Quality reviews became easier during audits or issues.

Operational control improved in day-to-day work, not just reports.
The improvement was visible on the floor.

Check out  how ManufApp’s Quality & Inspection ensures consistent batch approvals

Conclusion

ManufApp and Zoho now function as a single, connected system.

Issues that previously surfaced late are now caught early or avoided altogether.
Teams spend less time fixing data and more time running production.

The setup supports scale without adding complexity.