Malek Foam

Malek Foam Industry (Pvt) Ltd, a leading player in the foam and mattress manufacturing sector, was previously operating on the Odoo Community Edition, utilizing only the Accounting module. As the business scaled, they encountered several operational bottlenecks due to lack of process integration and automation:

·       Disjointed inventory control, leading to stock discrepancies and material shortages

·       Absence of Material Requirements Planning (MRP) for production forecasting and procurement alignment

·       Inability to measure channel-wise profitability, limiting strategic sales analysis

·       Complex product variant management, particularly in handling customized mattress dimensions and features

·       Manual production costing, with limited visibility over true manufacturing expenses

·       Lack of customized production reporting for sub-sections such as foam cutting, layering, quilting, and packaging

·       Manual logistics and dispatch processes, causing delays and inefficient fleet utilization

·       No system-based delivery tracking or customer communication, impacting service quality and partner coordination

Solution Delivered by RASCO Global Solutions

To address these pain points, RASCO Global Solutions (RGS) implemented a tailored Odoo Enterprise ERP solution that integrated and automated key manufacturing and logistics operations. The implementation included:

·       Sales & Purchase Management – Structured order lifecycle and vendor workflows

·       Inventory & MRP – Real-time inventory tracking with automated procurement and replenishment planning

·       Manufacturing & Variant Handling – BOM-driven production tailored for configurable mattress and foam product lines

·       Accounting Integration – Seamless financial automation linked with operational flows for real-time cost visibility

·       Channel-Wise Profitability Analytics – Dashboards to analyze performance across retail, wholesale, and export segments

·       Production Reporting by Sub-Section – Customized reporting for each production unit, improving operational oversight

·       Fleet & Dispatch Management – Introduction of logistics automation for dispatch scheduling, load planning, and fleet tracking

·       3rd-Party SMS Platform Integration – Auto-generated notifications for dispatch alerts to business partners and customers

Business Impact & Outcomes

The Odoo ERP implementation provided Malek Foam Industry with a modern, integrated system that significantly improved operational efficiency and decision-making:

·       End-to-end production visibility with structured reporting and performance tracking

·       Improved order fulfillment and delivery reliability, powered by integrated fleet and dispatch workflows

·       Greater cost control through accurate product costing and profitability breakdowns

·       Enhanced partner and customer communication, boosting satisfaction and trust

·       Streamlined planning and resource allocation, reducing waste and improving throughput

Digital Transformation for Complex Manufacturing

With Odoo Enterprise, Malek Foam Industry now operates with full digital oversight of its production, inventory, and logistics operations. Powered by RASCO Global Solutions, this transformation has equipped the company to scale efficiently, meet customer demands, and maintain a competitive edge in the foam and mattress industry.