Precision Under Pressure: How Sona Extrusion Boosted Manufacturing Efficiency by 30% and Mastered Compliance
About Sona Extrusion
Sona Extrusion Pvt. Ltd. is the silent engine behind many major brands, manufacturing essential aluminum packaging like collapsible tubes, flasks, and bottles. Serving high-stakes industries like pharmaceuticals, cosmetics, and nutraceuticals, they operate in a world where hygiene, precision, and strict regulatory compliance are non-negotiable.
Challenge
Managing a diverse production line for regulated sectors is a high-wire act, and Sona Extrusion was trying to balance it with manual tools.
- The Compliance Nightmare: Producing for pharma means drowning in paperwork. Their manual reporting for regulatory standards was slow and prone to errors.
- Production Paralysis: Inefficient planning meant they often faced downtime, leading to increased costs and delayed shipments.
- Inventory Blindness: Limited visibility into raw materials caused frequent stockouts, halting production lines unexpectedly and inflating inventory costs.
Solution
Reformiqo deployed ERPERA (Powered by ERPNext) to act as the central nervous system for their manufacturing plant.
- Streamlined Production: We digitized their production planning, aligning workflows to minimize downtime and maximize output.
- Smart Procurement: We implemented real-time inventory tracking to eliminate stockouts, ensuring the raw materials were always ready for the machines.
- Automated Compliance: We built automated reporting tools specifically to handle the strict standards of the pharmaceutical industry, turning days of paperwork into instant reports.
Results
By replacing manual chaos with digital precision, Sona Extrusion achieved remarkable operational improvements:
- ⚙️ 30% Higher Efficiency: Streamlined production planning significantly boosted overall plant output.
- ⏱️ 25% Less Downtime: Better planning meant machines—and people—were idle far less often.
- 📉 20% Lower Inventory Costs: Real-time tracking eliminated the need for “safety hoarding” and stopped stockouts cold.
- ⚡ 50% Faster Reporting: Compliance reports that used to take days are now generated in half the time.
- ✅ 40% Better Accuracy: Order processing errors were drastically reduced, ensuring customers got exactly what they asked for.
“ERPERA empowers Sona Extrusion to lead in precision manufacturing, ensuring excellence at every step of the process.” — Management, Sona Extrusion Pvt. Ltd.
