Real factory proof
Real incidents we saw in corrugated factories. Names and details are changed for privacy.
Story 1: “7% scrap was written as 3%”
In one factory, WO expected scrap was around 3%. Actual scrap was closer to 7% repeatedly. But the scrap numbers were written in notebooks — smaller than reality — to avoid questions.
What was happening
Operators kept partial reels near machine, scrap moved quietly to scrap area, and management saw only “normal” scrap in reports.
How ERPBro fixes it
WO close requires scrap entry + reason + optional photo. ERPBro compares expected vs actual and shows patterns by machine/shift/vendor.
Story 2: “₹1 Crore dead stock aged silently”
Store issued reels that were near the door, not FIFO. Over months, some reels aged beyond safe use and became scrap.
What was happening
No aging dashboard, no FIFO suggestions, and no alerts. Dead investment stayed invisible until it became scrap.
How ERPBro fixes it
Aging buckets (90/180/365), use-first suggestions, and owner alerts with monthly interest loss on dead investment.
Story 3: “Missed invoice found during ITR filing”
Dispatch happened for multiple deliveries, but invoice for one delivery was missed. It was discovered months later during audit.
What was happening
Dispatch team and accounts team were working in different systems. There was no automatic “dispatch vs invoice” check.
How ERPBro fixes it
Invoice-gap exception: if dispatch is done and invoice is not created within SLA, ERPBro flags it the same day.
Want to see your factory’s “hidden stories” using ERPBro data?
ERPBro converts daily work into management intelligence — and shows the WHY behind profit and loss.