How Rajkot Valve Castings Stopped 18% Scrap Leakages

Rajkot Valve Castings runs a batch-production foundry supplying valve components to industrial buyers across Gujarat and Maharashtra. Before working with Shiv Bow, raw steel scrap was tracked entirely on paper logs maintained per shift, with no way to reconcile how much raw material entered a batch against how much finished product actually left the line.

That gap meant scrap leakage — steel that was logged as consumed but never actually converted into a finished valve — was effectively invisible until the monthly stock count, by which point 18% of raw material value had quietly disappeared into unaccounted waste, theft, or measurement error.

Over a week of video walkthroughs with the floor team, our architects mapped every physical handoff point in the casting process: raw billet intake, furnace charge, mould pour, and finished-part inspection. We then deployed BowERP's Bill of Materials engine configured to the exact recipe of each valve SKU, paired with barcode scanners at each handoff point so that every gram of raw material entering the line is matched against a specific batch ID from intake through to finished-goods.

Within 30 days of go-live, Rajkot's management could see scrap variance per batch, per shift, and per operator for the first time. Leakage dropped by 18% in the first quarter alone, and the factory now flags any batch exceeding its expected scrap tolerance in real time rather than discovering it a month later.