A supplement manufacturer cuts lot traceability from a week to under an hour
Batch-level traceability, quality holds and Shopify and Amazon sync on ERPNext for a contract and private-label supplement maker.
- to trace any lot, down from a week
- < 1 hr
- to trace any lot, down from a week
- raw-material write-offs
- −35%
- raw-material write-offs
- sales channels on one stock ledger
- 3
- sales channels on one stock ledger
- to go-live
- 10 weeks
- to go-live
The client
Lumen Leaf makes capsules, powders and gummies under its own label and for other brands. Each finished lot draws on dozens of ingredient lots, and customers and auditors expect a full trace on request.
The challenge
- ✕Ingredient lots were recorded on paper batch records, so a trace meant a week of searching filing cabinets.
- ✕Raw materials expired in the warehouse because nobody could see shelf life across lots.
- ✕Shopify, Amazon and wholesale orders each had their own stock numbers, leading to oversells.
- ✕Accounting ran in QuickBooks, disconnected from production and inventory.
The solution
Formula-based BOMs
Master formulas with ingredient tolerances, yields and allergen flags, versioned and approved before release.
Lot and expiry control
Every receipt gets a lot, supplier certificate and expiry date, and first-expiry-first-out picking is enforced.
Quality holds
Incoming and finished lots sit in quarantine until quality release, with test results attached.
One-click trace
Forward and backward trace reports from any ingredient lot to every customer shipment, and back.
Channel and accounting integration
Shopify and Amazon orders flow into ERPNext; QuickBooks history was migrated and retired.
How we delivered
- 01Process mapping on the production floor alongside quality and warehouse leads.
- 02A pilot on two product lines before rolling out the full catalogue.
- 03Mock recall exercises run on the new system before go-live.
- 04Training by role: warehouse, production, quality and finance.
The results
- ✓A full forward and backward trace now takes under an hour.
- ✓Raw-material write-offs fell 35% in the first six months.
- ✓Oversells across Shopify, Amazon and wholesale stopped.
- ✓Month-end moved from QuickBooks exports to a same-week close.
“Our last mock recall took one afternoon instead of a week, and the auditor asked which consultant set it up.”