{"id":1843,"date":"2026-03-27T01:51:19","date_gmt":"2026-03-27T01:51:19","guid":{"rendered":"https:\/\/aaxonix.com\/resources\/?post_type=case_study&#038;p=1843"},"modified":"2026-03-27T04:27:40","modified_gmt":"2026-03-27T04:27:40","slug":"sheet-metal-stamping-unit-dispatch-accuracy-job-costing-zoho","status":"publish","type":"case_study","link":"https:\/\/aaxonix.com\/resources\/case-studies\/sheet-metal-stamping-unit-dispatch-accuracy-job-costing-zoho\/","title":{"rendered":""},"content":{"rendered":"<style>\n.cs-body{max-width:900px;margin:0 auto;padding:32px 0 56px;color:var(--muted);font-size:16px;line-height:1.85;}\n.cs-body h1{font-family:'Fraunces',serif;font-size:clamp(26px,3.5vw,40px);font-weight:900;color:var(--ink);line-height:1.15;margin:0 0 8px;}\n.cs-body h2{font-family:'Fraunces',serif;font-size:clamp(19px,2.4vw,26px);font-weight:800;color:var(--ink);margin:2.8em 0 .8em;line-height:1.2;}\n.cs-body 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h3{font-family:'Fraunces',serif;font-size:18px;font-weight:800;color:var(--orange);margin:0 0 10px;}\n.cs-takeaway p{font-size:15px;line-height:1.7;color:rgba(255,255,255,.82);margin:0;}\n.cs-faq{margin:2em 0;}.cs-faq-item{border-bottom:1px solid var(--bdr);padding:18px 0;}.cs-faq-item:last-child{border-bottom:none;}\n.cs-faq-q{font-family:'Fraunces',serif;font-size:16px;font-weight:700;color:var(--ink);margin:0 0 8px;}\n.cs-faq-a{font-size:14.5px;color:var(--muted);margin:0;line-height:1.7;}\n@media(max-width:768px){.cs-snapshot{grid-template-columns:repeat(2,1fr);}.cs-problem-grid{grid-template-columns:1fr;}.cs-sol-row{grid-template-columns:1fr;}.cs-ba-table{font-size:12.5px;}.cs-ba-table th,.cs-ba-table td{padding:8px 10px;}.cs-stats-grid{grid-template-columns:1fr;}}\n<\/style>\n\n<div class=\"cs-body\">\n\n  <span class=\"cs-eyebrow\">Auto Ancillary \u00b7 Sheet Metal Stamping<\/span>\n  <h1>How a Sheet Metal Stamping Unit Achieved 97% Dispatch Accuracy with Zoho<\/h1>\n\n  <!-- Snapshot tiles -->\n  <div class=\"cs-snapshot\">\n    <div class=\"cs-snap-tile\">\n      <div class=\"cs-snap-label\">Revenue Band<\/div>\n      <div class=\"cs-snap-val\">&#8377;18&#8211;24 Cr \/ yr<\/div>\n    <\/div>\n    <div class=\"cs-snap-tile\">\n      <div class=\"cs-snap-label\">OEM Customers<\/div>\n      <div class=\"cs-snap-val\">6 OEMs<\/div>\n    <\/div>\n    <div class=\"cs-snap-tile\">\n      <div class=\"cs-snap-label\">Press Lines<\/div>\n      <div class=\"cs-snap-val\">14 Stampings<\/div>\n    <\/div>\n    <div class=\"cs-snap-tile\">\n      <div class=\"cs-snap-label\">Go-Live<\/div>\n      <div class=\"cs-snap-val\">11 Weeks<\/div>\n    <\/div>\n  <\/div>\n\n  <!-- The Problem -->\n  <h2>The Problem<\/h2>\n  <div class=\"cs-problem-grid\">\n\n    <div class=\"cs-problem-card\">\n      <div class=\"cs-pc-icon\">\n        <!-- Lucide: package-x -->\n        <svg viewBox=\"0 0 24 24\"><path d=\"M21 10V8a2 2 0 0 0-1-1.73l-7-4a2 2 0 0 0-2 0l-7 4A2 2 0 0 0 3 8v8a2 2 0 0 0 1 1.73l7 4a2 2 0 0 0 2 0l2-1.14\"\/><path d=\"M16.5 9.4 7.55 4.24\"\/><polyline points=\"3.29 7 12 12 20.71 7\"\/><line x1=\"12\" y1=\"22\" x2=\"12\" y2=\"12\"\/><line x1=\"17\" y1=\"17\" x2=\"22\" y2=\"17\"\/><line x1=\"22\" y1=\"17\" x2=\"22\" y2=\"22\"\/><line x1=\"17\" y1=\"22\" x2=\"22\" y2=\"22\"\/><\/svg>\n      <\/div>\n      <h3>Consignment Mix-ups<\/h3>\n      <p>Six OEM consignments tracked in separate Excel sheets caused part-number confusion at dispatch. Wrong grades and quantities shipped 2&#8211;3 times per week, triggering debit notes and OEM line stoppages.<\/p>\n    <\/div>\n\n    <div class=\"cs-problem-card\">\n      <div class=\"cs-pc-icon\">\n        <!-- Lucide: tool -->\n        <svg viewBox=\"0 0 24 24\"><path d=\"M14.7 6.3a1 1 0 0 0 0 1.4l1.6 1.6a1 1 0 0 0 1.4 0l3.77-3.77a6 6 0 0 1-7.94 7.94l-6.91 6.91a2.12 2.12 0 0 1-3-3l6.91-6.91a6 6 0 0 1 7.94-7.94l-3.76 3.76z\"\/><\/svg>\n      <\/div>\n      <h3>Die Maintenance Blind Spot<\/h3>\n      <p>Die service intervals were tracked on paper job cards. Unscheduled breakdowns halted press lines for 4&#8211;8 hours at a stretch. There was no visibility into which die was approaching its stroke limit.<\/p>\n    <\/div>\n\n    <div class=\"cs-problem-card\">\n      <div class=\"cs-pc-icon\">\n        <!-- Lucide: calculator -->\n        <svg viewBox=\"0 0 24 24\"><rect x=\"4\" y=\"2\" width=\"16\" height=\"20\" rx=\"2\"\/><line x1=\"8\" y1=\"6\" x2=\"16\" y2=\"6\"\/><line x1=\"16\" y1=\"10\" x2=\"16\" y2=\"14\"\/><line x1=\"8\" y1=\"10\" x2=\"8\" y2=\"10\"\/><line x1=\"12\" y1=\"10\" x2=\"12\" y2=\"10\"\/><line x1=\"8\" y1=\"14\" x2=\"8\" y2=\"14\"\/><line x1=\"12\" y1=\"14\" x2=\"12\" y2=\"14\"\/><line x1=\"8\" y1=\"18\" x2=\"12\" y2=\"18\"\/><\/svg>\n      <\/div>\n      <h3>No Job-wise Costing<\/h3>\n      <p>Material, tooling amortisation, and press-time costs were never rolled up per job order. Month-end costing consumed two days of the accounts team&#8217;s time and still produced estimates that varied &#177;18% from actuals.<\/p>\n    <\/div>\n\n  <\/div>\n\n  <!-- The Solution Stack -->\n  <!-- INTERNAL LINK 1: Zoho Inventory (H2 section: The Solution Stack) -->\n  <!-- INTERNAL LINK 2: Zoho Books (H2 section: The Solution Stack) -->\n  <!-- INTERNAL LINK 3: Zoho Creator (H2 section: The Solution Stack) -->\n  <h2>The Solution Stack<\/h2>\n  <div class=\"cs-solution-stack\">\n\n    <div class=\"cs-sol-row\">\n      <div class=\"cs-sol-badge\">\n        <span class=\"cs-sol-product\">Zoho Inventory<\/span>\n        <span class=\"cs-sol-module\">Dispatch &amp; Stock Control<\/span>\n      <\/div>\n      <div class=\"cs-sol-body\">\n        <h3>Barcode-gated OEM Consignment Dispatch<\/h3>\n        <ul>\n          <li>Each finished part scanned against OEM-specific packing lists; <a href=\"https:\/\/aaxonix.com\/products\/zoho-inventory\/\" class=\"sp-content-link\">Zoho Inventory<\/a> blocks mismatched part numbers at the gate.<\/li>\n          <li>Lot-wise coil grade and thickness attributes recorded at goods receipt, carried forward through every operation.<\/li>\n          <li>Daily consignment delivery challans auto-generated per OEM; e-way bill data pre-filled from Inventory to Books.<\/li>\n          <li>Safety-stock alerts configured per OEM blanket order, preventing last-minute short shipments.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-sol-row\">\n      <div class=\"cs-sol-badge\">\n        <span class=\"cs-sol-product\">Zoho Books<\/span>\n        <span class=\"cs-sol-module\">Job Costing &amp; GST<\/span>\n      <\/div>\n      <div class=\"cs-sol-body\">\n        <h3>Real-time Job Order Cost Sheets<\/h3>\n        <ul>\n          <li>Material consumption posted directly from Inventory pick transactions; no double entry.<\/li>\n          <li>Tooling amortisation rules configured per die life (stroke count basis) and auto-charged to the job via <a href=\"https:\/\/aaxonix.com\/products\/zoho-books\/\" class=\"sp-content-link\">Zoho Books<\/a>.<\/li>\n          <li>Labour and press-time overhead applied via configurable allocation rate per press line per shift.<\/li>\n          <li>GST reconciliation for consignment returns and debit notes handled natively; monthly GSTR-1 generated in minutes.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-sol-row\">\n      <div class=\"cs-sol-badge\">\n        <span class=\"cs-sol-product\">Zoho Creator<\/span>\n        <span class=\"cs-sol-module\">Die PM Tracker<\/span>\n      <\/div>\n      <div class=\"cs-sol-body\">\n        <h3>Stroke-based Preventive Maintenance App<\/h3>\n        <ul>\n          <li>Custom app built with <a href=\"https:\/\/aaxonix.com\/products\/zoho-creator\/\" class=\"sp-content-link\">Zoho Creator<\/a> captures current stroke count per die after each press run; remaining life displayed on shop-floor kiosk.<\/li>\n          <li>Automated PM work orders raised in Zoho Projects when a die crosses 85% of rated stroke life.<\/li>\n          <li>Die repair history, spare consumption, and downtime logged; data feeds into Books cost allocation.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-sol-row\">\n      <div class=\"cs-sol-badge\">\n        <span class=\"cs-sol-product\">Zoho Projects<\/span>\n        <span class=\"cs-sol-module\">Maintenance Scheduling<\/span>\n      <\/div>\n      <div class=\"cs-sol-body\">\n        <h3>Planned vs Unplanned Maintenance Visibility<\/h3>\n        <ul>\n          <li>PM tasks assigned to maintenance technicians with due-date enforcement; overdue tasks escalate to plant head via automated mail.<\/li>\n          <li>Planned downtime windows coordinated with production planning so press schedule absorbs maintenance slots.<\/li>\n          <li>Monthly maintenance score card (planned vs breakdown ratio) shared with management via Projects dashboard.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n  <\/div>\n\n  <!-- Before vs After -->\n  <h2>Before vs After<\/h2>\n  <table class=\"cs-ba-table\">\n    <thead>\n      <tr>\n        <th>Area<\/th>\n        <th class=\"before\">Before Zoho<\/th>\n        <th class=\"after\">After Zoho<\/th>\n      <\/tr>\n    <\/thead>\n    <tbody>\n      <tr>\n        <td>Dispatch accuracy<\/td>\n        <td class=\"before\">~79% &#8212; wrong part or qty 2&#8211;3&#215;\/week<\/td>\n        <td class=\"after\">97% &#8212; barcode gate blocks errors at source<\/td>\n      <\/tr>\n      <tr>\n        <td>Die PM compliance<\/td>\n        <td class=\"before\">Ad-hoc; breakdown-driven repairs only<\/td>\n        <td class=\"after\">Stroke-triggered PM; 5&#215; fewer unplanned stoppages<\/td>\n      <\/tr>\n      <tr>\n        <td>Job costing cycle<\/td>\n        <td class=\"before\">2 days\/month; &#177;18% variance from actual<\/td>\n        <td class=\"after\">Live cost sheet per job; &lt;3% variance<\/td>\n      <\/tr>\n      <tr>\n        <td>OEM debit notes<\/td>\n        <td class=\"before\">8&#8211;12 per quarter from dispatch errors<\/td>\n        <td class=\"after\">1&#8211;2 per quarter; mainly transit damage<\/td>\n      <\/tr>\n      <tr>\n        <td>Coil lot traceability<\/td>\n        <td class=\"before\">Paper bin cards; recall took half a day<\/td>\n        <td class=\"after\">Lot traced to OEM shipment in under 2 minutes<\/td>\n      <\/tr>\n      <tr>\n        <td>GST reconciliation<\/td>\n        <td class=\"before\">Manual matching of challans vs invoices<\/td>\n        <td class=\"after\">Auto-matched; GSTR-1 filed day after month close<\/td>\n      <\/tr>\n      <tr>\n        <td>Maintenance visibility<\/td>\n        <td class=\"before\">No dashboard; plant head learned of breakdowns post-facto<\/td>\n        <td class=\"after\">Live die health kiosk + escalation alerts<\/td>\n      <\/tr>\n    <\/tbody>\n  <\/table>\n\n  <!-- Implementation Phases -->\n  <!-- INTERNAL LINK 4: Manufacturing industry page (H2 section: Implementation Phases) -->\n  <h2>Implementation Phases<\/h2>\n  <div class=\"cs-timeline\">\n\n    <div class=\"cs-tl-item\">\n      <div class=\"cs-tl-badge\">1<\/div>\n      <div class=\"cs-tl-content\">\n        <div class=\"cs-tl-title\">Data Foundation &amp; Item Master <span class=\"cs-tl-dur\">Weeks 1&#8211;2<\/span><\/div>\n        <ul>\n          <li>Audited and cleaned 6 OEM part masters; standardised part codes and drawing revision suffixes.<\/li>\n          <li>Configured coil grade, thickness, and supplier attributes in Zoho Inventory item master.<\/li>\n          <li>Mapped 14 press lines as locations; defined routing-based cost centres in Books. This implementation approach is common across our <a href=\"https:\/\/aaxonix.com\/industries\/manufacturing\/\" class=\"sp-content-link\">manufacturing<\/a> engagements.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-tl-item\">\n      <div class=\"cs-tl-badge\">2<\/div>\n      <div class=\"cs-tl-content\">\n        <div class=\"cs-tl-title\">Inventory, Dispatch &amp; Books Go-live <span class=\"cs-tl-dur\">Weeks 3&#8211;6<\/span><\/div>\n        <ul>\n          <li>Barcode labels introduced at coil receipt; scan-based pick and pack flows configured per OEM.<\/li>\n          <li>Job order templates built in Books with material, tooling amortisation, and overhead cost lines.<\/li>\n          <li>E-way bill integration tested against live GST sandbox; debit note workflow configured.<\/li>\n          <li>Parallel-run period: team operated old Excel and Zoho simultaneously to validate accuracy.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-tl-item\">\n      <div class=\"cs-tl-badge\">3<\/div>\n      <div class=\"cs-tl-content\">\n        <div class=\"cs-tl-title\">Creator Die Tracker &amp; Projects PM <span class=\"cs-tl-dur\">Weeks 7&#8211;9<\/span><\/div>\n        <ul>\n          <li>Zoho Creator app built with die register, stroke counter, and repair log forms; kiosk view deployed on shop-floor tablet.<\/li>\n          <li>PM task templates created in Zoho Projects; stroke threshold triggers automated task creation via Creator workflow.<\/li>\n          <li>Maintenance technicians trained on task acceptance, spare logging, and closure sign-off.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n    <div class=\"cs-tl-item\">\n      <div class=\"cs-tl-badge\">4<\/div>\n      <div class=\"cs-tl-content\">\n        <div class=\"cs-tl-title\">Cutover, Reporting &amp; Stabilisation <span class=\"cs-tl-dur\">Weeks 10&#8211;11<\/span><\/div>\n        <ul>\n          <li>Excel parallel run discontinued; all dispatch and costing moved exclusively to Zoho.<\/li>\n          <li>Management dashboards published: dispatch accuracy trend, planned vs breakdown ratio, job-wise margin.<\/li>\n          <li>Hypercare support for two weeks post go-live; remaining punch-list items closed within stabilisation window.<\/li>\n        <\/ul>\n      <\/div>\n    <\/div>\n\n  <\/div>\n\n  <!-- Results -->\n  <!-- INTERNAL LINK 5: Case Studies page (H2 section: Results) -->\n  <h2>Results<\/h2>\n  <div class=\"cs-stats-grid\">\n    <div class=\"cs-stat-card\">\n      <div class=\"cs-stat-num\" id=\"cs-counter-1\" data-target=\"97\" data-suffix=\"%\">97%<\/div>\n      <div class=\"cs-stat-lbl\">Dispatch Accuracy Achieved<\/div>\n    <\/div>\n    <div class=\"cs-stat-card\">\n      <div class=\"cs-stat-num\" id=\"cs-counter-2\" data-target=\"5\" data-suffix=\"&#215;\">5&#215;<\/div>\n      <div class=\"cs-stat-lbl\">Fewer Unplanned Tool-Die Stoppages<\/div>\n    <\/div>\n    <div class=\"cs-stat-card\">\n      <div class=\"cs-stat-num\" id=\"cs-counter-3\" data-target=\"9.6\" data-prefix=\"&#8377;\" data-suffix=\"L\" data-decimals=\"1\">&#8377;9.6L<\/div>\n      <div class=\"cs-stat-lbl\">Annual Job-Costing Effort Saved<\/div>\n    <\/div>\n  <\/div>\n\n  <div class=\"cs-chart-wrap\">\n    <p class=\"cs-chart-title\">Key Metrics &#8212; Before vs After<\/p>\n    <canvas id=\"cs-chart-1\" height=\"160\"><\/canvas>\n  <\/div>\n\n  <!-- Takeaway -->\n  <div class=\"cs-takeaway\">\n    <h3>The Core Insight<\/h3>\n    <p>Dispatch errors and tooling breakdowns in sheet metal stamping share the same root cause: no system of record at the shop floor. Once every die stroke, every coil lot, and every OEM consignment had a digital identity in Zoho, the errors stopped because the system simply would not allow them to pass through. Accuracy became the default, not a target. Explore more outcomes like this in our <a href=\"https:\/\/aaxonix.com\/case-studies\/\" class=\"sp-content-link\">case studies<\/a>.<\/p>\n  <\/div>\n\n  <!-- FAQs -->\n  <h2>Frequently Asked Questions<\/h2>\n  <div class=\"cs-faq\">\n\n    <div class=\"cs-faq-item\">\n      <p class=\"cs-faq-q\">How does Zoho Inventory handle multiple OEM consignment packing standards?<\/p>\n      <p class=\"cs-faq-a\">Each OEM is set up as a separate customer with its own packing list template, part-number format, and label layout in Zoho Inventory. When a dispatch is initiated, the system validates the scanned part against the specific OEM&#8217;s approved part list and raises a hard block if there is a mismatch. OEM-specific e-way bill and challan formats are configured once and applied automatically to every subsequent shipment.<\/p>\n    <\/div>\n\n    <div class=\"cs-faq-item\">\n      <p class=\"cs-faq-q\">Can Zoho Creator track die life on a stroke count basis without custom hardware?<\/p>\n      <p class=\"cs-faq-a\">Yes. The Creator app records the stroke count logged by the press operator at the end of each run &#8212; no sensor integration is required to start. As the operation matures, the stroke counter can be pulled automatically from press PLCs via the Creator API, but the manual entry model alone is sufficient to drive the PM trigger logic and has worked well for stamping units with 10&#8211;20 press lines.<\/p>\n    <\/div>\n\n    <div class=\"cs-faq-item\">\n      <p class=\"cs-faq-q\">How is tooling amortisation handled in Zoho Books for job costing?<\/p>\n      <p class=\"cs-faq-a\">A die asset record is created in Books with its total rated life in strokes and acquisition cost. A per-stroke amortisation rate is derived automatically. When a job order is completed, the stroke count consumed is entered and Books applies the proportionate tooling cost to the job cost sheet alongside material and labour. This gives an accurate per-part cost without any end-of-month manual allocation.<\/p>\n    <\/div>\n\n    <div class=\"cs-faq-item\">\n      <p class=\"cs-faq-q\">What does the GST workflow look like for consignment returns and OEM debit notes?<\/p>\n      <p class=\"cs-faq-a\">When an OEM raises a debit note for a short or wrong shipment, a credit note is created in Zoho Books against the original invoice. The credit note reverses the GST liability and feeds into the GSTR-1 amendment workings. Consignment returns are handled as return receipts in Inventory, which automatically creates the corresponding reversal entry in Books and updates stock levels &#8212; the accounts team does not need to make any manual journal entries.<\/p>\n    <\/div>\n\n  <\/div>\n\n<\/div>\n\n<script>\n(function(){\n  var CU = (typeof countUp !== 'undefined' && countUp.CountUp) ? countUp.CountUp : (typeof CountUp !== 'undefined' ? 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