Client Overview

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

The product range is wide and keeps changing. BOMs are not static. A small mistake in components or tracking often shows up much later, usually during testing or dispatch. Zoho Books was already used for accounting, but production data reached it late or not at all.

Manufacturing Setup

HBeon runs a multi-stage electronics assembly setup with:

SMT machines
DIP machines
Kit issue section
Testing stations
Assembly, QA, and packing lines

Several SKUs move through the floor at the same time. Stores, production, and quality teams all 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 for components once material entered stores.
• Manual GRN and consumption entries into Zoho caused delays and frequent mismatches.
• Purchase and sales tracking lacked a fixed structure. Data was spread across systems and spreadsheets.
• BOM-based kit issuance errors were common and often caught 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

Key Benefits Delivered to HBeon

1. Lot & Rack-Wise Tracking of All Materials

Every inward material is now tagged with a lot number and rack location.
Stores teams can see exactly where material is kept and which lot is being issued.
When issues arise, tracing 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 the actual purchase cost.

This ensures:
Correct lot pricing
Accurate consumption costing
Clean COGS sync into Zoho
No end-of-month 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. Vendor performance is easier to review using actual lot data.

4. IQC (Incoming Quality Check) & Inspection List

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

This gives:
Standardized testing
Clear batch-wise approval or rejection
Digital quality records
Direct linkage between IQC and material availability

5. Barcode Printing for Each Individual Item

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 Accuracy & Error-Free Kit Issuance

Kit issuance is controlled strictly by BOM.
Wrong component issues are blocked at stores itself.

This reduced:
Line stoppages
Rework
Mid-assembly corrections

7. Real-Time Financial Accuracy in Zoho

Because every movement syncs automatically, Zoho always reflects actual shop floor data.

Stock levels stay accurate.
COGS matches production reality.
Sales values no longer need reconciliation.

8. End-to-End Traceability from Inward to Dispatch

Each device can now be traced from component inward to final dispatch.
When questions come up, data is already there.

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 work as a single system for HBeon.

Problems that earlier appeared late are either caught early or avoided completely.
Teams spend less time fixing data and more time running production.

The setup supports growth without adding confusion.