Case Studies
Custom Odoo 15 Manufacturing ERP for BPW-LAB
Miami, FL | Nutritional Supplement Manufacturing | FDA-Compliant | GMP-Certified
Odoo 15 Enterprise (Full Custom Implementation) · Formula calculator engine, FDA recall system, automated quote-to-production pipeline, GMP manufacturing automation, executive intelligence layer
Executive Summary
Before
A $15M+ Miami-based nutritional supplement manufacturer operating on a patchwork of disconnected systems. Product formulations in Excel, version-controlled by email. Quality assurance on paper checklists. No systematic recall capability -tracing affected lots meant hours of manual investigation. Sales had no visibility into manufacturing capacity; manufacturing had no visibility into incoming orders. Executive dashboards were spreadsheets updated every Friday.
After
- ✓Fully integrated FDA-compliant manufacturing ERP: sales rep builds a product formula, calculates full landed cost with MOQ pricing, generates a digitally-signed quote, and triggers the complete manufacturing workflow in under 10 minutes.
- ✓Quality control embedded at every stage: video evidence, metal detection compliance, premix verification, 90-minute automated QC checks, and instant lot-level recall queries across the supply chain.
- ✓186+ features across 16 custom modules and 9 custom PDF reports delivered with 94% task completion rate over 12+ months of continuous delivery.
- ✓CEO Dashboard with real-time KPIs across sales, manufacturing, quality, procurement, and inventory -strategic decision cycle reduced from monthly to weekly, working capital efficiency up 22%.
The Challenge
Miami-based nutritional supplement manufacturer running manual spreadsheet formulations, disconnected quality processes, and no product recall capability — transformed into a fully digital, FDA-compliant manufacturing ERP with automated quote-to-production pipeline.
Spreadsheet Formula Factory -Product formulations lived in Excel workbooks with version numbers in filenames and email chains confirming which was current. Sales reps manually inputted ingredient costs into proposal templates. Manufacturing received BoMs as exported PDFs. No reliable way to track which orders were based on which formula version -compliance risk was high and scalability was zero.
Quality Control Blind Spots -Paper-based checklists and email confirmations with no digital evidence of what happened on the shop floor during packaging, QC, or batch testing. Metal detector scans logged on paper, premix verification by manual sign-off. FDA audits required days of manual document compilation from folders of scanned documents and fragmented emails.
The Recall Gap -No systematic way to trace a product lot from raw material through production, packaging, shipment, to customer. If a batch failed metal detection or a complaint arrived, answering 'which customers received material from this batch?' required manual detective work, spreadsheet pivots, and phone calls. Operational and compliance risk they couldn't even quantify.
Sales-to-Manufacturing Disconnect -Quote went to customer, then someone manually transposed the formula into a manufacturing order. If the formula changed after the quote, nobody tracked it. Insufficient inventory? The order still went to manufacturing to improvise. Lead times were unpredictable because manufacturing had no visibility into incoming demand until orders arrived by email.
Executive Visibility Black Hole -CEO dashboards were spreadsheets updated sporadically by a 'numbers guy' every Friday. No real-time insight into product profitability, sales rep performance, actual inventory levels, or manufacturing status. Strategic decisions were made on gut feel and last month's numbers.
The Solution
The Formula Calculator Engine -Custom cost calculation tool embedded in the CRM/Sales pipeline with two specialized calculators (Chews and Powders). Inputs ingredient list, quantities, packaging, MOQ -instantly computes raw material costs, manufacturing labor, packaging, testing fees, compliance overhead, freight, and MOQ-based tiered pricing. Sales rep iterates in real-time and generates a digitally-signed PDF quote without leaving Odoo. 2,000+ quotes processed, turnaround time 48h → under 10 minutes.
FDA-Aligned Quality & Recall System -Video evidence capture via tablets time-stamped to batch records. Metal detector reporting with regulatory formatting. Premix verification workflow. 90-minute automated recurring QC checks. Complaint → Recall workflow instantly queries affected lots, customers, FDA classification, and recall scope -then generates a task list with corrective actions. 6+ FDA-level recalls managed with 100% lot traceability and zero escapes.
Automated Quote-to-Production Pipeline -CRM Opportunity → Calculator → digitally-signed Quote → Auto-BOM creation → Sales Order with MOQ pricing → Manufacturing Order with supplier lot traceability, batch tracking, and auto-generated GMP cleaning orders → Quality Control → Delivery with container label printing and LOT tracking → Customer Portal access with certificates of analysis. Zero manual data re-entry, perfect end-to-end traceability.
GMP-Compliant Manufacturing Automation -The aznut_mrp module (82+ iterative releases) delivers batch-level ingredient tracking, automated cleaning orders between product runs with checklists and supervisor sign-offs, BOM audit history with PLM version control, enhanced production order PDFs with ingredient images and supplier details, and integrated container label printing with LOT tracking. Manufacturing throughput predictability +35%, inventory write-offs -98%, zero GMP audit findings.
Executive Intelligence Layer -Single-screen CEO Dashboard with real-time widgets: Sales KPI (YTD revenue, top-margin products, pipeline, conversion), Manufacturing (WIP, on-time delivery, cycle time, quality pass), Quality (defect rate, supplier score, recall incidents, audit readiness), Procurement (supplier performance, inventory turnover, cost variance), Inventory (stock by location, slow-movers, recall quarantine), CRM (pipeline, deal probability, CSAT). Strategic decision cycle: monthly → weekly. Working capital efficiency +22%.
Modules Implemented
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