Kirloskar Smart Inward-Outward

Real-Time Material Visibility with SAP Barcoding: Kirloskar Brothers Success Story

Client Profile: Kirloskar Brothers Ltd.

Kirloskar Brothers Limited (KBL) is a flagship company of the Kirloskar Group and a globally recognized manufacturer of pumps, valves, hydro turbines, and fluid management systems. With manufacturing plants, warehouses, and project sites across India and overseas, Kirloskar Brothers operates in high-volume, asset-intensive environments where accuracy, traceability, and operational efficiency are critical.

To streamline plant-level material movement and eliminate manual inefficiencies, Kirloskar Brothers partnered with BSC Global to implement a Smart Inward–Outward Barcoding Solution fully integrated within SAP.

Business Challenges

Kirloskar Brothers faced multiple operational challenges in managing material movement:

  • Manual Inward–Outward Processes using registers and spreadsheets
  • Limited Real-Time Visibility of material movement within plants and warehouses
  • Data Mismatch Between Physical Stock and SAP
  • Delayed Goods Receipt (GR) and Goods Issue (GI) postings
  • Higher Risk of Human Errors, duplication, and unauthorized movements
  • Difficulty in Audit Tracking and reconciliation during inspections

Solution Implemented by BSC Global

BSC Global designed and implemented a Smart Inward–Outward Barcoding Solution embedded inside SAP, enabling seamless digitization of material movements.

Key Solution Components

1. SAP-Integrated Barcoding Framework

  • Barcoding solution fully integrated with SAP MM & WM processes
  • Real-time synchronization between physical movement and SAP transactions

2. Smart Inward Process

  • Barcode generation at the time of:
    • Purchase Order receipt
    • Gate entry
  • Barcode scanning to:
    • Validate PO, material, quantity
    • Post Goods Receipt (MIGO) in SAP
  • Automatic update of inventory and batch details

3. Smart Outward Process

  • Barcode-based validation for:
    • Production issue
    • Stock transfer
    • Customer dispatch
  • SAP-linked Goods Issue postings
  • Elimination of manual outward registers

4. Gate Entry & Security Integration

  • Controlled inward–outward movement through barcode scanning at gates
  • Reduced unauthorized material movement

5. Real-Time Dashboards & Reports

  • Live tracking of inward and outward materials
  • SAP-based reports for:
    • Daily inward–outward summary
    • Pending receipts
    • Dispatch status

6. Audit & Compliance Enablement

  • Complete traceability of material movement
  • Easy audit trails with SAP logs and barcode scans

Implementation Approach

  • Process Study & Gap Analysis of existing inward–outward workflows
  • SAP Custom Enhancements for barcode integration
  • Hardware Integration (barcode scanners & printers)
  • User Training & SOP Enablement for plant and warehouse teams
  • Go-Live Support & Stabilization

Business Outcomes & Benefits

  • 90% Reduction in Manual Data Entry
  • Real-Time Inventory Visibility across plants and warehouses
  • Improved Accuracy in GR/GI Posting
  • Faster Material Movement & Reduced Turnaround Time
  • Stronger Internal Controls & Audit Readiness
  • Enhanced Productivity of Stores & Security Teams
  • Seamless SAP Adoption without External Systems

Why Kirloskar Brothers Chose BSC Global

  • Deep expertise in SAP MM, WM, and plant-level digitization
  • Proven SAP-native barcoding solutions
  • Strong understanding of manufacturing & engineering industries
  • Ability to deliver scalable and audit-ready solutions

Conclusion

With BSC Global’s Smart Inward–Outward Barcoding Solution inside SAP, Kirloskar Brothers Ltd. successfully transformed its material movement operations from manual to digital. The solution delivered real-time visibility, improved accuracy, and stronger governance, enabling Kirloskar Brothers to operate with greater efficiency, control, and confidence across its manufacturing ecosystem.