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Food Manufacturing ERP & Intelligent Store Management Solution

Ayoni Foods Pvt. Ltd. is a food processing and consumer goods manufacturing enterprise based in Rajkot, Gujarat, India, specializing in instant noodles, packaged savory snacks, seasonings, and flour-based food products.

With continuous multi-shift factory lines and distributed production warehouses running high-speed manufacturing, Ayoni Foods operates in a fast-paced environment where raw ingredient freshness, strict recipe adherence, exact batch lot tracking, and granular consumption auditing are paramount to profitability, brand reputation, and food safety standards.

Company Name

Ayoni Foods Pvt. Ltd.

Location

Rajkot, Gujarat

Industry

FMCG / Food Manufacturing

The Challenge

Before partnering with Micra Digital, Ayoni Foods faced significant operational bottlenecks across their manufacturing shop floor, inventory store, and sales order fulfillment:

Lack of Store Department Governance & Unauthorized Consumption — Raw materials were being issued from the store without proper approval workflows, causing inventory discrepancies and cost overruns.
No Automated FIFO/FEFO Lot Allocation & Expiry Risks — Lots were selected manually without enforcing first-expiry rules, risking expired ingredient usage in food products.
Inaccurate Material Consumption, Returns & Food Wastage Auditing — No mechanism existed to track gram-level consumption adjustments or record wastage accurately per batch.
Fragmented Sales Demands & Uncoordinated Production Batches — Sales orders were not consolidated into production plans, resulting in machine downtime and missed delivery windows.
Absence of Recipe Variation Tolerance Limits — Without tolerance controls, variations in recipe ingredient quantities led to inconsistent product quality and packaging weight.
Shift-Wise Tracking Blind Spots & Inability to Roll Back Finished Orders — No shift tagging on production orders made accountability impossible; no mechanism existed to undo a completed manufacturing order.

Requirements

To overcome these challenges, Ayoni Foods required a specialized Odoo ERP solution with the following capabilities:

Store Approval Workflow
Interactive Consumption Adjustment Wizard
Automatic FIFO/FEFO Lot Assignment
Lot/Batch Selection Wizard
Sales-to-Manufacturing Demand Engine
Multi-Warehouse Bill of Materials (BoM) Mapping
Recipe Tolerance & Percentage Variation Limits
Mandatory Shift Tagging
Production Reset & Rollback Mechanism
Real-Time Store Dashboard & QWeb PDF Reports

The Solution

Micra Digital developed a customized Odoo 19.0 ERP module for Ayoni Foods, structured around seven core pillars that address every bottleneck in their manufacturing and store operations:

Two-Tier Store Approval & Production Locking: A dual approval workflow ensures store managers validate all raw material issuances before production begins. Approved production orders are locked to prevent unauthorized modifications.

Interactive Consumption Adjustment & Wastage Engine: An interactive wizard allows store staff to record actual consumption, adjustments, returns, and wastage per batch at gram-level precision.

Automated FIFO/FEFO Lot Allocation & Batch Selection Wizard: The system automatically selects raw material lots based on First-Expiry-First-Out rules, with a wizard for manual batch overrides when required.

Sales Demand Planning & Order Aggregation Engine: Open sales orders are automatically aggregated into optimized production batches, minimizing machine setup time and maximizing throughput.

Multi-Warehouse BoM Mapping & Recipe Tolerance Controls: Bills of Materials are mapped per warehouse location; percentage-based tolerance limits enforce recipe compliance across all production runs.

Multi-Shift Management & Production Rollback Architecture: Mandatory shift tagging on every production order enables accountability reports. A rollback mechanism allows completed orders to be reset when quality or quantity issues are detected.

Executive Store Dashboard & QWeb Consumption Reporting: Real-time store dashboards give management instant visibility into stock levels, consumption, and wastage, with QWeb PDF reports for compliance audits.

The Result

With Micra Digital's customized Odoo 19.0 solution, Ayoni Foods experienced measurable improvements across manufacturing, store governance, and food safety compliance:

100% Store Reconciliation

Unauthorized raw material issuance dropped to zero with the two-tier store approval and production locking mechanism.

Gram-Level Wastage Tracking

Real-time tracking of usage, returns, and wastage for accurate batch costing across every production shift.

Planning Efficiency Boost

Consolidated production planning reduced machine downtime and setup delays across all factory lines.

Strict FIFO & Expiry Compliance

Automated lot selection reduced expired stock risks and supported food safety compliance requirements.

Recipe Tolerance & Yield Control

Variance limits ensured consistent production, weight, flavour, and packaging across all product lines.

Shift Transparency & Audit Reports

Mandatory shift tracking and QWeb PDF reports improved accountability across 24/7 multi-shift operations.

The Impact

60%

Increase in planning efficiency

24/7

Shift Tracking & Accountability

100%

Store Reconciliation