Business Requirement

The client was running core finance and inventory on a generic ERP setup that was not built for food manufacturing. This created recurring operational risk across the plant and the supply chain: 

• No batch-level traceability — raw material batches from suppliers could not be reliably traced through production into finished-goods batches, making recalls slow and audits difficult. 

• Manual, inconsistent quality checks — inspections for incoming raw materials, in-process goods, and finished products were tracked on spreadsheets and paper, with no standard acceptance criteria or approval workflow. 

• Expiry and shelf-life leakage — without FEFO (First-Expiry-First-Out) enforcement or expiry alerts, near-expiry stock was often missed, leading to wastage and forced discounting. 

• Disconnected production planning — production schedules were built without a clear link to sales orders, MRP, seasonality, or shelf-life constraints, causing over-production of slow movers and stockouts of fast movers. 

• Limited visibility into true profitability — costing was tracked at a general ledger level, not by batch, so the client could not tell which production runs or products were actually profitable once yield loss, rework, and scrap were factored in. 

CCS Solution

CCS designed and implemented a Food Industry Automation solution built on SAP Business One, extending the core ERP with food-specific controls across the operational chain: 

• Batch and expiry-controlled inventory — food-specific item attributes (allergen classification, cold-storage requirements, shelf life), warehouse classification (QC, Quarantine, Cold Storage, Non-Saleable), and bin-level tracking, with FEFO validation and automated near-expiry alerts. 

• QC-gated procurement — vendor rating and compliance-document tracking, vehicle inspection, and goods receipt that stays blocked until required inspections are completed, preventing non-compliant material from entering stock. 

• Structured quality control framework — configurable testing templates, inspection plans, acceptance criteria (including AQL and defect classification), a dedicated QC screen for raw materials, WIP, and finished goods, and CAPA workflows for recurring failures. 

• Demand- and shelf-life-aware production planning — production scheduling driven by open sales orders and MRP, recipe/formula-based BOMs with expected-vs-actual yield tracking, customer-specific BOM versions, and stage-wise tracking of rework, co-products, by-products, and scrap. 

• FMCG-ready sales and distribution — scheme and discount management, batch-wise sales tracking with backward traceability to production, and structured handling of expired and damaged returns through QC. 

• Batch-wise costing and profitability reporting — raw material, processing, and packaging costs rolled up to the batch level, with actual-vs-standard variance and product-level profitability analysis. 

• Integration with plant and lab systems — weighing scales, barcode/QR generation and scanning, and laboratory/LIMS systems feeding directly into SAP Business One, removing manual re-entry at the shop floor and lab.