Executive Summary
A leading mattress manufacturer faced inefficiencies in production planning, stock management, and quality control. By implementing Odoo ERP, we automated BOM approvals, optimized raw material consumption, enabled real-time inventory tracking, and strengthened quality checks. The result was reduced production delays, accurate material planning, and improved product consistency.
About the Client
The client is a mattress manufacturing company specializing in high-volume production of foam, spring, and hybrid mattresses. With growing demand and multiple product variants, the company needed a robust ERP solution to streamline production, manage raw materials efficiently, and ensure strict quality control across manufacturing stages.
Challenges Faced
Inefficient Production Planning
Manual scheduling caused frequent delays in order fulfillment.
Raw Material Wastage
Lack of visibility into foam, fabric, and spring usage increased costs.
Inventory Blind Spots
Limited real-time tracking across warehouses led to stockouts and overstocking.
Quality Control Gaps
Mattress durability and comfort checks were inconsistent.
BOM Inaccuracies
Complex BOMs for different mattress models caused errors in cost estimation and production.
ERP Solution Implemented
We deployed Odoo ERP with custom features designed for mattress manufacturing:
BOM Approval Workflow
Multi-stage validation for accurate mattress BOMs.
Raw Material Optimization
Real-time consumption tracking for foam, springs, and fabrics.
Inventory & Warehouse Control
Centralized tracking with batch-wise visibility.
Integrated Quality Checks
QC embedded at every stage – from foam cutting to final stitching.
Production Flow Automation
Sales Order → BOM → Manufacturing Order linkage for seamless planning.
Costing & Pricing Tool
Operation-level cost insights for better margin control.
Implementation Journey
Process Study
Mapped mattress production stages (foam cutting, quilting, assembly, finishing).
ERP Customization
Configured Odoo manufacturing, inventory, and QC modules for mattress-specific needs.
Integration
Automated SO → MO process with BOM approvals and inventory reservations.
Pilot & Training
Deployed in one unit, scaled to multiple plants, with hands-on team training.
Results & ROI
Results & ROI
25% Faster Production Cycles
Automated scheduling reduced delays.
30% Reduction in Material Wastage
Optimized consumption of foam and fabrics.
Improved Traceability
Batch-level tracking enhanced inventory accuracy.
Higher Quality Consistency
QC integration reduced defects and returns.
Accurate Costing
BOM validations and costing tools improved pricing strategy.
Conclusion & Future Outlook
The Odoo ERP implementation enabled the mattress manufacturer to gain end-to-end visibility, reduce costs, and deliver high-quality products on time. Looking forward, the client plans to integrate IoT-enabled machinery monitoring and a customer warranty management module to further enhance production and after-sales support.
Join Us Today
Mattress manufacturing involves complex workflows and high material costs. With Odoo ERP, you can automate production, optimize material usage, and ensure quality at every stage. Contact us to see how we can help streamline your manufacturing operations.