Manufacturing Digital Transformation: STAR's Complete ERP & Task Management

The Challenge: Manual Friction vs. Scaling Growth

Since 1988, STAR Engineering has been a leader in automotive electronic components. However, scaling operations across multiple plants revealed deep-seated bottlenecks in their manual ecosystem:

• Data Fragmentation: Disconnected spreadsheets and paper records created “information silos.”
• Inventory Blind Spots: Frequent production halts due to manual stock-tracking errors.
• Attendance Fraud: Traditional biometrics were prone to “proxy attendance.”
• Communication Gaps: WhatsApp groups buried critical manufacturing tasks and deadlines.

[!NOTE] The goal wasn’t just to add software, but to create a single source of truth for 500+ engineers working in diverse environments.

The Solution: A Unified Digital Ecosystem

We designed a dual-platform strategy that bridges the gap between the production floor and the back office:

1. STAR ERP (Web): The central nervous system for procurement, inventory, and finance.
2. STAR FollowUp (Mobile): An AI-driven field app for task tracking, communication, and HRMS.

🏢 Strategic ERP Operations (Web)

Optimizing the core business engine through automation:

• Smart Inventory: Real-time visibility into 10,000+ SKUs with automatic reorder triggers.
• Digitized Procurement: Automated requisition-to-invoice workflows with vendor portals.
• Financial Intelligence: Integrated GST compliance and automated expense reconciliation.

📱 Field Intelligence & HRMS (Mobile)

Empowering engineers where they work:

• AI Attendance: On-device face recognition (TensorFlow Lite) preventing attendance fraud.
• Task Orchestration: Kanban-style task tracking with dependencies and real-time alerts.
• Contextual Communication: Built-in chat and Minutes of Meeting (MOM) documentation.

Engineering Excellence: The Tech Stack

To ensure 99.9% uptime and handle diverse device performance, we leveraged a high-resiliency architecture:

• AI at the Edge: Used TensorFlow Lite on mobile for privacy-preserving, sub-2s face verification.
• Resilient Backend: Node.js microservices on AWS with auto-scaling to handle peak traffic.
• Data Integrity: PostgreSQL for complex transactional logic across multi-plant operations.
• Offline First: React Native sync architecture allowing field work even in zero-connectivity zones.

React Native

Node.js

PostgreSQL

TensorFlow Lite

AWS

Measurable Business Impact

The results of the digital transformation were immediate and quantifiable:

Metric	Improvement	Impact
Operational Efficiency	+60%	Higher production throughput
Inventory Costs	-40%	Reduced excess stock holdings
Manual Data Entry	-80%	Reclaimed hundreds of man-hours
Attendance Accuracy	100%	Eliminated all proxy fraud cases
Procurement Cycle	-50%	Faster vendor order processing

Why This Project Succeeded

• Vertical Expertise: We mapped software to actual manufacturing shop-floor workflows.
• Mobile-First Adoption: By putting HRMS tools in the hands of mobile engineers, adoption reached 100%.
• Phased Rollout: Starting with inventory/purchase provided immediate ROI before scaling to HRMS and production.

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