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Manufacturing

Unifying Operations Across 4 Plants with a Custom ERP

Vertex Manufacturing ran four plants on a patchwork of legacy desktop software, spreadsheets, and manual registers. 7x Technologies designed and rolled out a custom ERP that unified production, inventory, procurement, and finance into a single real-time platform.

.NET 8ReactPostgreSQLAzureDockerTally Integration

Results

9 days to 2 days
Month-end close time
99.2%
Inventory accuracy
-63%
Order processing time
-70%
Manual data entry effort

The Challenge

Vertex Manufacturing, an auto-components maker with four plants across the NCR and Pune, had grown faster than its systems. Each plant ran its own instance of an ageing desktop ERP, procurement lived in email threads and Excel, and the finance team re-keyed data from plant reports into Tally every month. Inventory figures were reliable only on the day of a physical count, and month-end close routinely stretched past nine working days.

Leadership had no consolidated view of work-in-progress, raw material exposure, or plant-level profitability. Quoting new orders was guesswork because true production costs were only known weeks after dispatch. An off-the-shelf ERP had been evaluated twice and rejected — the licence cost was prohibitive and it could not model Vertex's job-work and subcontracting flows without heavy customisation anyway.

The Solution

7x Technologies ran a six-week discovery across all four plants, mapping every material and document flow before writing a line of code. The team then built a modular ERP on .NET 8 and PostgreSQL, with a React front end designed for shop-floor use — large touch targets, barcode-first workflows, and offline tolerance for patchy plant Wi-Fi. Modules covered production planning, stores and inventory, procurement, quality, dispatch, and a finance layer with a two-way Tally integration so the accounts team kept their existing books.

The platform was containerised with Docker and deployed on Azure, with each plant syncing to a central instance so head office dashboards always reflected live data. Handheld barcode scanners at goods-inward and dispatch points eliminated manual registers, and every material movement now posts to inventory in real time.

Rollout was deliberately phased: the Manesar plant went live first as a pilot, and lessons from six weeks of hypercare were folded into the templates used for the remaining three plants. All four sites were live within eleven months, with 7x running train-the-trainer programs so Vertex's own supervisors owned adoption on the floor.

Client testimonial

“7x Technologies replaced four disconnected systems with a single ERP that our plant managers actually enjoy using. Month-end reporting that used to take nine days now closes in two, and for the first time we have a live view of inventory across every location.”

Rajesh KhannaChief Executive Officer, Vertex Manufacturing

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