Polyplastics Industries is a leading Indian manufacturer of automotive components and assemblies for OEMs. Known for its dynamic and progressive approach, the Polyplastics Group delivers value-added products, services, and innovative solutions across the automotive industry and beyond. With a diversified product portfolio, the company supports multiple sectors—primarily the automotive segment—through continuous innovation and high-quality production.

Product Portfolio Includes:

• Emblems (Electroplated, Painted, Gold Plated & Hot Stamped)
• Automotive Plastic Molded Components
• Wheel Trims & Covers
• Electroplated Parts (Radiator Grills, License Plate Garnish, Hood Strips)
• Decorative Body Side Moldings
• Assemblies: Control Brackets, Auto Electrical Assemblies, Dashboard Components
• Door Handles, Fuse Box Assemblies, Diesel Water Separators
• Injection Molding Tools

Business Challenge

Before implementing IFS ERP, Polyplastics relied on manual procurement and production planning processes. Due to the high volume and complexity of components and assemblies, the company faced recurring challenges such as:

• Frequent inventory mismatches and inefficiencies
• Difficulty in maintaining optimal stock levels
• Complex manufacturing cycles with poor production visibility
• Lack of integration between departments and real-time operational insight
• Delayed responsiveness to customer demand and internal reporting needs

Solution

After a detailed evaluation of ERP vendors, Polyplastics selected IFS Applications as its enterprise solution partner. The implementation aimed to reduce production costs and inventory levels, shorten cycle times, improve delivery performance, and provide better access to real-time data for agile decision-making.

The implemented solution consists of:

• Manufacturing Process – Product BoM, Creation of Shop order, labor reporting, Shop floor reporting, Quality control.
• MRP and MS for material planning
• Customer Schedules/Customer Order and Invoicing
• Purchasing, Inter site Transfer (CO-PO cycle)
• Finance – Accounts receivable, Accounts Payable, General Ledger, Fixed Assets
• Taxation including Excise, Service Tax and Sales tax
  
  
  Implemented IFS Modules:
  IFS Manufacturing
  IFS MRP/MS
  IFS Distribution
  IFS Financials
  IFS Human Resources
  IFS Payroll
  
  
• IFS Version: Applications 8 SP1 with India Localization
• Go-Live Year: 2010
• Implementation Footprint: 8 plants across different locations in India

Impact

Since implementing IFS ERP, Polyplastics has transformed its manufacturing and operational efficiency:

• Improved Inventory Management: Accurate material planning eliminated overstocking and stockouts
• Reduced Operational Costs: Streamlined workflows and better planning led to significant cost savings
• On-Time Delivery: Integrated scheduling and customer portals improved delivery accuracy
• Real-Time Integration: Direct connection with major automobile customers for dispatch schedules and invoice updates
• Better Visibility: Enhanced insights into sales, stock levels, shop floor activities, and cash flow
• Scalable Expansion: The ERP system now supports 8 manufacturing plants across India