Surya Roshni digital case

PwC India has published a case study on a factory software rollout at Surya Roshni that replaced manual pipe measurement, pricing and order workflows in the company’s steel pipe business. (pwc.in) The case says Surya Roshni was managing more than 18,000 finished-material custom codes in pipe manufacturing, with batch-to-batch variation in conversion units such as kilograms to grams for thickness and length. It also says channel partners wanted invoices in different measurement units, which the old process could not automate. (pwc.in) PwC said it implemented a SAP-based system after pipe quality inspection, using batch-specific units of measurement, weighbridge integration and tolerance rules to calculate actual weight through production. The case also says the system added custom pricing logic based on standard conversions stored in the material master. (pwc.in) In plain terms, the problem was that one pipe can be sold by size, weight and customer-specific invoice format at the same time. When those conversions are handled by spreadsheets and plant staff instead of software, pricing errors, stock mismatches and planning delays become more likely. (pwc.in) PwC’s case says Surya Roshni also struggled with manual tracking of letters of credit, credit management tied to changing exchange rates, custom packaging requests and pipe stock movement between plants. Orders could be taken at one plant while semi-finished goods were produced at another, which the company said made end-to-end make-to-order planning difficult. (pwc.in) The timing fits a much larger push in Indian manufacturing to build what consultants call a “digital backbone” before adding analytics or artificial intelligence. PwC’s India manufacturing research says 54% of firms show an upward implementation trend in analytics and artificial intelligence, while 38% have yet to create a digital transformation roadmap. (pwc.in) Surya Roshni is large enough for these shop-floor changes to matter. The company says it started with steel tubes in 1973, now sells steel pipes, PVC pipes, lighting and home appliances, and reported FY 2024-25 sales of ₹7,435.22 crore with exports to more than 50 countries. (surya.co.in) Its steel business remains the core industrial engine. In its FY25 results release, Surya Roshni said steel pipes hit record fourth-quarter volume of 2.6 lakh tons and an all-time high annual volume of 8.77 lakh tons in FY25. (nseindia.com) The same FY25 materials show the pressure on execution. Surya Roshni’s directors’ report said the steel and pipes segment posted revenue of ₹5,749.07 crore in FY 2024-25, down 7.89% from ₹6,241.78 crore a year earlier, citing slower demand for high-value-added products. (economictimes.indiatimes.com) That makes this case study less about a new app than about standardizing the arithmetic of manufacturing — how long a pipe is, how much it weighs, what price follows, and which plant fulfills the order. For factories running mixed product lines and cross-plant production, that is the work that decides whether volume turns into clean invoices and on-time shipments. (pwc.in)