60% Less Production Downtime with Odoo MRP

The Challenge

A North American industrial component manufacturer producing precision parts for the aerospace and automotive sectors was running production planning in Excel and managing maintenance logs on paper. Production orders were often issued with incorrect or outdated Bills of Materials, leading to material wastage and rework. On-time delivery to customers was only 71% — causing contractual penalties and customer attrition. Equipment breakdowns were reactive rather than preventive, causing unplanned downtime averaging 18 hours per month.

The Solution

Bytesfuel implemented Odoo 18 with Manufacturing (MRP), Quality Control, Maintenance, Inventory, and Purchase modules. A custom BOM versioning module was built to enforce Engineering Change Order (ECO) approvals before production. Preventive maintenance schedules were configured for all 24 work centers, triggering scheduled maintenance work orders automatically.

The Results

• 60% reduction in unplanned downtime — preventive maintenance eliminated the most common breakdown causes within 3 months.
• On-time delivery improved from 71% to 94% — accurate production scheduling and reliable material availability drove this improvement.
• 35% less material wastage — BOM version control ensured production always used approved quantities.
• Full ROI achieved in month 7 — savings from reduced downtime, scrap, and rework exceeded the total project investment.

"The Bytesfuel team understood our manufacturing floor from day one. The Odoo MRP system they built for us gave us visibility we never had before. Our customer complaints about late deliveries dropped by 80% in the first quarter."