BUSINESS BACKGROUND
A growing food manufacturing company producing packaged nutritious products from agricultural raw materials operated across several plants and managed a mix of distributor, retail, and selective D2C sales channels. Its operations involved raw material procurement, batch-based production cycles, and multi-stage RM to WIP to FG processes.
As demand increased and the product portfolio expanded, the business needed a stronger financial and inventory structure to support high raw material consumption, continuous processing workflows, detailed costing and margin visibility, and payroll management for more than 50 employees. Accurate financial controls became critical for pricing decisions, capacity planning, and overall operational efficiency.
KEY CHALLENGES
The company’s growth exposed several operational and financial gaps that limited accuracy, control, and timely decision-making.
- Unreliable tracking of RM, WIP, and FG due to spreadsheets and paper-based logs
- No structured reconciliation between consumption, production, and closing stock
- Bulk posting of bank and credit card entries creating unclear cash positions
- Manual payroll for 50+ employees increasing errors and compliance concerns
- Limited visibility into product-wise and plant-wise profitability
- Finance team functioning reactively, focused on fixing discrepancies instead of supporting decisions
REQUIREMENTS & EXPECTATIONS
The company needed a partner who could take full ownership of accounting and inventory management while bringing structure, accuracy, and discipline to fast-growing operations. The requirements included:
- A consistent and disciplined RM, WIP, and FG inventory tracking system
- Monthly reconciliations aligned with physical stock counts
- Reliable and compliant payroll processing
- Regular updating and reconciliation of bank and credit card transactions
- A structured month-end close process
- Detailed costing insights to guide pricing, procurement, and production decisions
GATP Solutions was selected for its demonstrated manufacturing expertise and its ability to build strong financial control systems. The company valued GATP’s experience in implementing accurate costing models, establishing tight inventory processes, and providing reliable financial visibility needed to support scaling operations.
GATP’S STRATEGIC APPROACH
To stabilize operations and build a reliable financial backbone, GATP Solutions implemented a structured, end-to-end framework that strengthened controls across production, inventory, and accounting.
Process and Data Flow Mapping
- Documented the complete movement of materials from procurement to finished goods to create transparency across plants
- Assessed accounting entries, payroll processes, and banking workflows to understand baseline practices
- Highlighted process gaps, inconsistencies, and areas where data accuracy and internal controls needed improvement
Master Creation and Policy Setup
- Created standardized masters for RM, PM, FG, GL accounts, and cost centers to unify data across all facilities
- Defined clear policies for material valuation, overhead absorption, wastage norms, and consumption rules, ensuring consistent financial treatment
Inventory Control Framework
- Established disciplined processes for GRNs, material issues, production reporting, stock adjustments, and scrap recording
- Introduced monthly reconciliation cycles for RM, WIP, and FG to maintain accurate inventory positions and reduce discrepancies
Finance Operations Calendar
- Built a structured monthly calendar covering banking updates, payroll timelines, inventory closure, and reporting cycles
- Enabled predictable workflows, allowing the finance function to shift from reactive issue resolution to proactive planning and oversight
COMPREHENSIVE SOLUTION
GATP Solutions implemented a fully structured financial and inventory framework that aligned with the company’s manufacturing processes and growth needs. Each functional area was redesigned to bring consistency, accuracy, and timely insights.
A. Inventory Management and RM/WIP/FG Reconciliation
A disciplined inventory model was introduced to strengthen visibility across raw materials, production cycles, and finished goods.
- Implemented item-wise and location-wise tracking across all plants
- Captured material issues and batch-level production output for accurate costing
- Conducted monthly reconciliations comparing book stock with physical counts
- Introduced yield analysis and variance reports to highlight inefficiencies
B. Full Accounting Operations
GATP managed the company’s complete accounting function to ensure reliable financial reporting.
- Handled day-to-day entries across purchases, expenses, and sales
- Posted accruals, provisions, and closing entries for accurate monthly books
- Developed a manufacturing-focused chart of accounts tailored to multi-stage processes
C. Bank and Credit Card Updating
To eliminate cashflow uncertainty, banking processes were streamlined.
- Implemented regular posting cycles for receipts, payments, and card expenses
- Conducted monthly or fortnightly reconciliations to maintain accurate balances
D. Payroll Processing for 50+ Employees
Payroll was centralized and automated to reduce manual errors and compliance risks.
- Consolidated attendance, overtime, and incentive inputs into a single workflow
- Automated payroll calculations for accuracy and consistency
- Delivered detailed department-wise payroll reports for management review
E. Month-End Close and Reporting
The month-end process was redesigned into a predictable, well-controlled cycle.
- Introduced a structured checklist covering all reconciliations and review points
- Delivered monthly P&L with product and plant-level visibility
- Provided a full balance sheet and manufacturing KPIs to support operational decisions
MEASURABLE RESULTS
GATP Solutions’ intervention delivered measurable improvements across inventory accuracy, financial controls, and operational visibility. The company moved from inconsistent processes to a fully structured system that supported confident decision-making.
- 100 percent RM, WIP, and FG reconciliation each month, giving the business full clarity on material movement and stock positions
- 35 percent reduction in stock variances and write-offs, driven by disciplined tracking, reconciliation cycles, and variance analysis
- Month-end close reduced from 12 days to 5 days, allowing leadership to review financial performance much earlier and plan ahead with confidence
- Stronger cash visibility through regular bank and credit card reconciliations, improving short-term planning and control
- Accurate, on-time payroll for all employees, supported by centralized data capture and automated calculations
- Clear product-wise and plant-wise profitability insights, helping the team make more informed decisions on pricing, capacity allocation, and production planning
This structured foundation significantly improved financial reliability, operational efficiency, and the company’s readiness for scale.
CALL TO ACTION
Manufacturers rely on accurate inventory, disciplined accounting, and reliable cost insights to scale with confidence. GATP Solutions delivers structured RM, WIP, and FG management, streamlined payroll, precise reconciliations, and a month-end reporting framework that strengthens financial visibility.
Looking to build stronger control and clarity across your operations?
Connect with the GATP team today at 
