Multi-level bills of material
Hold assemblies, sub-assemblies, phantom items, alternates, by-products and scrap factors in one structure, with revision control so an engineering change reaches planning and costing at the same time.
Manufacturing Solution
Manufacturing ERP from raw material to dispatch
Engineering, planning, procurement, the shop floor and finance work from one structure, so the bill of materials that a designer revises is the same one that plans the purchase order and carries the cost of the job it produced.
Material, labour and overhead post against each work order as it runs, so quoted margin and actual margin stop drifting apart.
One data model
Where the plan and the ledger stop disagreeing.
In most plants, the planning spreadsheet, the shop-floor register and the accounts package each hold a version of the same job. By the time they are reconciled, the job has shipped and the margin question is academic.
Because every module posts to one ledger, consumption booked at the machine is the consumption costed in finance, and the variance you are looking at on Friday is the variance that existed on Tuesday.
- One BOM and routing shared by engineering, planning, purchasing and costing
- Work-in-progress valued from bookings, not from a period-end estimate
- Lot and serial traceability followed from goods receipt through to dispatch
- Subcontract material tracked while it is outside your premises
- Purchase, production and sales orders visible against the same item master
What it covers
From the drawing to the dispatch note.
Discrete assembly and process batches are both first-class citizens here. The same modules cover a machine shop building to order and a plant running formulations against a batch record.
MRP and production planning
Explode firm and forecast demand against on-hand, on-order, lead times and lot sizes to produce a make-or-buy plan, then release work orders and purchase requisitions from the same run.
Shop-floor data capture
Book material issues, operation completions, machine and labour hours, scrap and rework against the work order as it happens, so job status is current instead of reconstructed at month end.
Quality control
Define inspection plans for incoming, in-process and final stages, record results against the lot or serial number, and hold, rework or reject material with the reason and inspector attached.
Landed and actual costing
Roll a standard cost from the BOM and routing, add freight, duty and clearing to landed cost, then post actual material, labour and overhead per work order so estimate and outcome sit side by side.
Vendor and subcontractor management
Track rate contracts and delivery performance, issue material to job workers under challan, see what is lying outside your gates, and reconcile the subcontractor's return against what you sent.
How a plant goes live
Prove it on one line first.
A manufacturing rollout that starts with the whole plant starts with the whole plant's risk. We configure against a real product family, run it in parallel, and widen from there.
01
Process and product mapping
We follow one product family end to end: how it is designed, planned, purchased, made, inspected, costed and shipped, and where the current handoffs lose information.
02
Masters, BOMs and routings
Item masters, units, BOM levels, routings, work centres, vendors and rate contracts are cleaned and loaded, then checked by the people who will have to live with them.
03
Pilot line in parallel
One line or product family runs live in the platform alongside the existing method, so bookings, consumption and costing can be compared against a known answer.
04
Plant-wide cutover
Remaining lines, stores and the quality function are brought on with opening stock, open work orders and open purchase orders carried across under supervision.
05
Costing and reporting tuning
Overhead absorption, variance analysis, WIP valuation and the management reports are tuned against real posted volume, then handed to your team with the training to maintain them.
Platform fundamentals
The record that survives the audit.
One BOM
Engineering, planning and costing read the same structure
Work order
Material, labour and overhead post against the job that used them
Batch trace
Lot and serial history followed from receipt through to dispatch
Plan to actual
Rolled cost and posted cost compared on the same record
Questions plants ask
Before the first work order.
Both. Discrete work orders against multi-level assemblies and process batches against formulations with by-products and yield variance are supported by the same production, quality and costing modules.
Bills of material are multi-level and support sub-assemblies, phantom items, alternates and scrap factors, with revision control so a change is applied from a defined effective point rather than retrospectively rewriting history.
Yes. Material issued for subcontracting stays visible as your stock while it sits with the job worker, and the returned quantity is reconciled against what was issued, including scrap and process loss.
Bookings are kept to what the operator can realistically record: issues, operation completion, time, scrap and rework. Entry points are configured per work centre so a machine operator is not asked to do a planner's job.
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See it on your product
Bring one job to the demo.
Pick a product family, a work order that went wrong and the costing you had to explain. We will walk it through the platform and show where each posting would have appeared.