VR Green is a young eco-friendly packaging MSME, ISO 9001/22001/14000 certified, producing compostable cups and bags. As production scaled up, the factory floor was still running on paper logs and spreadsheets — a paper-heavy operation managing eco-friendly products. They needed a single source of truth that matched the company's values.

VR Green's factory operations relied on a patchwork of paper logs, spreadsheets, and ad-hoc semi-digital tools. As production scaled, the cracks widened — leadership was flying blind, and floor teams were losing time to coordination overhead.

• Inefficiencies and delays in task assignments
• No real-time monitoring of production, machines, or attendance
• Poor coordination between production, inventory, and HR
• Difficulty generating performance reports

Conducted sessions with plant managers, supervisors, and floor operators to understand how the factory really runs day-to-day — not how the org chart says it should.

• Lack of visibility across departments
• No centralized dashboard
• Hard to track work orders and inventory

Studied ERPs used in similar industries — Odoo, SAP, Acumatica, and Workday — to map common modules, dashboard patterns, and the rising bar around sustainability KPIs and mobile-first access. Modern manufacturing ERPs increasingly bake in carbon tracking, vendor ESG scoring, and clean dashboards with drag-and-drop customization.

Designed for five distinct roles, each with very different tech comfort and goals — from a high-school-educated floor operator using a shared tablet to a director checking KPIs on his phone.

• Ramesh — Production Floor Operator (29): Low-to-moderate tech comfort. Needs simple, icon-driven task views and durable interface for noisy environments.
• Priya — Floor Supervisor / Plant Manager (38): Moderate tech. Needs live KPIs, drag-and-drop reassignments, fast approve/deny.
• Amir — Inventory/Store Manager (32): Moderate-high tech. Needs accurate, alert-driven stock visibility across warehouses and floors.
• Sunita — HR/Admin Officer (41): Moderate tech. Needs streamlined onboarding, attendance, compliance docs, role-based permissions.
• Mr. Verma — Director/Owner (45): Moderate tech. Needs executive-level KPIs, mobile access, scheduled reports.

Mapped the system into ten focused modules — each with a single, clear job — so each persona has an obvious entry point.

• Dashboard — KPIs, targets, pending requests, welcome
• Orders — current orders, history, add & edit, order actions
• Productions — ongoing & history, batch control, status, filters
• Manufacturing — assignments, batch details, machine/operator allocation
• Product Inventory — warehouse/floor view, item input/output, history log
• Duty Roster — floor/shift allocation, supervisor & operator/helper assignment
• Pending Requests — sign-in, leave, attendance approvals
• HR Portal — employee onboarding, directory, attendance/compliance
• Dispatch Log — shipment history, add shipment, delivery status
• Admin Panel — site config, user roles, audit logs, data management

Started on paper — quick low-fidelity sketches for Dashboard, Order screen, Sign Up, and Forms. Iterated into high-fidelity once the IA stabilized.

A welcome strip, four KPI tiles (Recent Orders, Orders in Progress, Machines in Use, Operator Attendance), a Daily Production Target donut, Pending Sign-In Requests with deny/approve, and a Recent Orders table with status pills. One screen — entire factory pulse.

Current Orders list with search, date range, and a + New Order button. Adding an order opens a side panel with customer, address, product, variant, quantity, pricing, priority, and description fields — including +Add More Product for multi-line orders.

Filterable production table by priority, status, and time period — with status chips for Completed, Pending, Processing, Shipped, Delivered, Cancelled, Returned. Detail view opens an editable batch form with order code, batch number, floor, variant, quality, and priority.

Same table-and-side-panel pattern, with a Machine column and an Add Manufacturing form that includes Assign New Machine — handling operator/helper allocation per machine.

Warehouse and finished-product views with reference order, variant, quantity, type, and last-updated. Add Item panel with product type, reference order, variant, quantity, quality, warehouse — and +Add More Item for batch entry.

A multi-block form for the three layers of factory authority — Floor Incharge, Supervisor (with floor/area/shift), and Machine Operator/Helper roles. + Add More Floor and + Add New Machine handle scaling without leaving the page.

A 5-step employee onboarding wizard — Personal Details → Address & Employment → Educational Qualifications → References → Document Uploads — with a vertical progress rail. Includes Indian compliance fields like UAN, ESIC, and Aadhaar uploads, so HR doesn't have to chase paperwork after the fact.

A component system designed for scale — sidebar variants (collapsed, expanded, with sub-items, dark theme), the full status-chip set, file upload state machine, and table row patterns. Built so the next module added doesn't need a single new component.

#14AE5C Industrial Green as primary — sustainability and growth, aligned with VR Green's brand identity. #0A1B2D Deep Blue as secondary — neutral depth without the harshness of pure black. Greys (#1E1E1E, #D9D9D9) for surfaces and structure.

Inter — open-source variable sans-serif, picked specifically for clarity in data-heavy environments. Variations used: Semi Bold, Medium, Regular. Sizes: 9pt, 7pt, 6pt — calibrated for dense tables without sacrificing legibility.

• Workers begin each day with clarity — assignments, targets, and shift status visible at a glance
• Bottlenecks and resource gaps surface in real time instead of in next week's report
• Inventory loss dropped and waste was curtailed — an ecological as much as economic win
• VR Green's sustainability values became visible inside the product itself, not just on the packaging