Case study / Electronics manufacturing
Connecting Global Procurement, High-Volume Manufacturing and Serialised After-Sales Operations
From imported components to serialised devices in the field — procurement, landed cost, multi-level BOMs, production, dealers, warranty and service on one connected thread.
- Global sourcing
- ~100,000 pcs / month
- Serialised devices
- Dealer + after-sales
- Industry
- Electronics manufacturing
- Production scale
- Approximately 100,000 pcs / month
- Workforce
- 1,000+ employees
- Sourcing
- China and other international suppliers
- Core areas
- Import · Serialised inventory · BOM · Production · Dealers · Warranty · Service · HRMS
[ The Turning Point ]
Watch theTransformation Story.
Go behind the systems and see the operating decisions that shaped the transformation.
[ The operation before ]
One device.Its history in many places.
At this scale, every device is the end of a long chain — and each link of that chain was recorded somewhere different.
- Import & costGlobal suppliers
- Purchase ordersForeign currency
- Duty & freightSeparate sheets
- Forex differenceBooked later
- MakeReceive · Build
- Component receiptsWithout serials
- AssembliesMulti-level BOMs
- Production lotsShop-floor records
- After the saleDealers · Service
- Dealer creditChecked by hand
- WarrantyInvoice lookup
- RepairsService register
Landed cost, serial history and warranty status are pieced together from separate records.
- Areas working apart
- 03
- Separate records
- 09
- Serial history in one place
- 00
[ Where it broke ]
Same component.Three different costs.
International purchasing brought foreign currency, import duties and exchange differences into every material cost — and the product cost was the last to know.
Duties and freight reached the costing sheet weeks after the goods.
The exchange difference at settlement never reached product cost.
Pricing kept using the supplier’s price.
- Duties and freight not yet in material cost
- Exchange difference at settlement never reaches product cost
Illustrative figures · ₹ / unit
[ How we approached it ]
Follow the device,then connect the chain.
Akhilam connected the device lifecycle end to end — landed cost at import, serial identity from receipt, BOMs behind production, and after-sales working from the same serial history.
- 01
Understand
Followed one device from a foreign-currency purchase to a warranty claim.
- 02
Design
One serial identity from receipt to service, with landed cost captured at import.
- 03
Connect
Import, BOM production, dealers, warranty, service and HRMS on one foundation.
- 04
Run
Accounting and controls aligned with Indian requirements across the whole flow.
What we built
- Global procurement
- Serially controlled GRN
- High-volume production
- Multi-level BOM
- Finished product serialisation
- End-to-end serial traceability
- Serial-number warranty claims
- Repair & service
- Dealer / distributor operations
- HRMS + payroll
- Putaway
- Indian accounting
[ The operating journey ]
One serial.Its whole life.
Follow one device from imported components to a warranty claim.
Components ordered from an international supplier in foreign currency
Duties, freight and the exchange rate build the landed cost
Received with serial numbers and put away to a known location
Built through sub-assembly and assembly on a multi-level BOM
Invoiced to a dealer within price and credit limits
Sold to a customer — the serial carries the history
A warranty claim is verified from the serial before repair
[ Process & capability exhibits ]
How the key processesnow work — try them.
Each exhibit is interactive. The values are illustrative; the logic is how the system works.
- Model
- Illustrative model
- Built
- Line 2 · Wk 38
- Status
- In service · warranty
Select any record to see its link to TV-2409-118342.
Illustrative serials and lots. Selecting a component lot shows every other device that used it — the basis of a targeted recall.
- Supplier price in ₹₹400.80
- Import duty₹60.12
- Freight & clearing₹12.00
Forex loss at settlement₹5.28
Illustrative rates and values. Duty treatment varies by product and is configured per item.
- Serial looked upTV-2409-118342passed
- Sale foundSold via dealer · 7 months agopassed
- Warranty periodWithin 12 monthspassed
- Prior claimsNonepassed
- DecisionApprovedpassed
Free repair approved. Parts used and resolution are recorded against the serial.
Illustrative claims.
Four dealer orders waiting.
Illustrative dealers and values (₹ lakh).
[ Before vs after ]
What changed,line by line.
- Before: Material cost at purchase priceAfter: Landed cost with duties and forex
- Before: Serials tracked on paper, if at allAfter: Serial identity from receipt onward
- Before: Requirements estimated at volumeAfter: Multi-level BOMs drive requirements
- Before: Warranty checked against invoicesAfter: Warranty verified from serial history
- Before: Dealer credit checked after the orderAfter: Pricing and credit limits at the order
- Before: HR and payroll on a separate islandAfter: HRMS and payroll on the same foundation
[ Business outcomes ]
What changed wasn't one process.It was how the whole operation runs.
- TraceableDevices linked by serial from receipt to service
- CostedLanded cost and forex carried into material cost
- StructuredMulti-level BOMs behind high-volume production
- VerifiableWarranty claims checked against serial history
- ControlledDealer pricing, credit and receivables
- ScalableOne foundation for volume, workforce and after-sales
Outcomes are described qualitatively. Figures appear only where validated by the business.
“Placeholder for a client-approved quote on what changed in running a high-volume operation.”
[ Go deeper ]
The ConnectedElectronics Manufacturer.
Our research and implementation perspective on global sourcing and landed cost, serialised inventory, multi-level BOM production, dealer networks, warranty and after-sales service.
- 01Global sourcing + landed cost
- 02Serial traceability + BOM production
- 03Dealers, warranty + service
Business email, first name and company — nothing more.
[ Could this be your business? ]
Shipping volume,losing the thread?
If several of these sound familiar, you are where this business was before one serial thread ran through the operation.
- You import components, and material cost ignores duty or forex.
- Finding a device’s history means searching several records.
- Multi-level assemblies make requirements hard to see.
- Warranty claims are checked against invoices, not the serial.
- Dealer credit and outstandings are managed outside the order.
[ Related capabilities ]
What made thistransformation possible.
- ManufacturingMaterial → batch → release.
- Procurement & Source-to-PaySupplier → procurement → payment.
- Warehouse & LogisticsReceipt → stock → fulfilment.
- Sales & RevenuePrice → order → receivable.
- HR & Workforce ManagementPeople → payroll → compliance.
- Finance & Source-to-PayTransaction → ledger → visibility.
[have a similar challenge?]
Your Business Won't Look Exactly Like This. That's the Point.
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