Make to stock
Produce to a forecast and sell from finished goods, so customers get delivery from the shelf.
For example: packaged food, FMCG, building products
Plans from forecasts, reorder levels and safety stock on finished goods
Manufacturing BOMs, production, quality, costing
From raw material to dispatch, on one ERP.
Plan production from real orders, run the shop floor on work orders and job cards, check quality at every gate and know what each unit cost to make. Purchase, stock, GST, accounts and your sales and service teams work on the same records.
- Discrete, batch and process
- Planned from sales orders
- Cost per unit, not a guess
Production plan · SO-2291LiveSample data
200Pumps ordered
3Work orders
2Items short
₹6,840Cost / pump
WO
Motor assembly × 200Sub-assembly · winding line · 64% done
RunningMR
Copper winding wire 1.2 mmProjected 340 kg · reorder at 400 kg
OrderedJW
Casting machining · job work180 of 200 back from Sai Engineering
At supplierQI
Final test · lot 11/26Pressure and current within limits
PassedTypes of manufacturing
Built for the way you make things.
Most factories mix two or three of these. We set BeatOS ERP up for the way each of your product lines is actually made.
Make to order
Nothing is made until the customer orders, and every order has a promised date.
For example: pumps, control panels, machined parts
Work orders straight from sales orders, with stock and capacity checked first
Engineer to order
Each order is designed for the customer, so the BOM is drawn up per job.
For example: special machines, fabrication, plant equipment
A project per order, its own BOM, and every cost charged to that project
Discrete and assembly
Countable units built from parts and sub-assemblies, often with a serial number each.
For example: electricals, auto components, furniture
Multi-level BOMs, serial numbers and warranty history per unit
Batch
Made in lots from a recipe, where every batch must be traceable and checked.
For example: chemicals, paints, pharma, food
Batch BOMs, batch numbers with expiry, and a quality check on every batch
Process
Continuous production from bulk raw material, where yield and loss decide the margin.
For example: polymers, edible oil, textile processing
Process loss, scrap and by-products recorded, and yield tracked per run
Repetitive
The same products run on dedicated lines, day after day, at a steady rate.
For example: packaging, castings, components
Standard routings, workstation capacity and daily output against plan
Not sure which you are?
Tell us how one product moves through your factory. We will map it in the first study.
How we study your process →The building blocks
Set up once. Every order uses it.
Six records describe how your factory works. After that, planning, costing and the shop floor all read from them.
- ItemsRaw materials, sub-assemblies, finished goods and services, with units and HSN codes.
- WorkstationsMachines and lines, with their hourly cost, working hours and how many jobs they run at once.
- OperationsEach step of the work, such as winding, machining or testing, done at a workstation.
- Bills of materialsWhat goes into a product and which operations make it, with sub-assemblies having their own BOMs.
- Work ordersAn instruction to make a quantity from a BOM. It reserves the material and lists the operations.
- Job cardsOne per operation on the shop floor, with time logged by operator and machine.
Multi-level BOMv3Sample data
- Submersible pump 1 HPFinished good× 1
- Motor assemblySub-assemblyown BOM
- Stator stampingsRaw material3.2 kg
- Copper winding wireRaw material1.4 kg
- Rotor shaftRaw material× 1
- Pump body, machinedJob workfrom casting
- ImpellersRaw material× 6
- Cable, gland and packingRaw material1 set
- Motor assemblySub-assemblyown BOM
Operations:WindingVarnishingAssemblyPressure testPacking
One order, end to end
Follow 200 pumps through the factory.
An example from a make-to-order pump maker. Each step creates a linked record, so anyone can open the order and see exactly where it stands.
Sell and plan
01Sales order
A dealer orders 200 pumps for the 30th, from the office or the rep's phone.
Sales orderSales
02Production plan
The plan opens the multi-level BOM and works out the motors to make and the material to buy.
Production planPlanner
03Material requests
Anything short after counting stock, orders and reservations goes to purchase.
Material requestPlanner
Buy and receive
04Purchase and receipt
Copper wire is ordered with approval and received with an incoming check; rejects go to a separate store.
Purchase orderReceiptPurchase, stores
05Job work
Castings go to a machining job worker; their stock is tracked until the bodies come back.
Subcontracting orderPurchase
06Issue to the shop floor
Material for each work order moves from stores to work in progress.
Stock entryStores
Make and check
07Motor work order
Motors are wound and varnished first, as a sub-assembly with its own work order.
Work orderProduction
08Job cards
Each operation is logged at its workstation, with time and operator, so delays show the same day.
Job cardOperators
09Final assembly and test
Pumps are assembled, then pressure-tested against limits before they are accepted.
Quality inspectionQuality
Ship and close
10Finished goods
Each pump enters stock with its own serial number, for warranty and service later.
Stock entryStores
11Dispatch and invoice
Delivery note, GST e-invoice and e-way bill go out together.
Delivery noteInvoiceDispatch, accounts
12Cost and service
Actual cost per pump is compared with the plan; service visits later find the pump by serial.
CostingAccounts, service
Making something different?Batch and process plants follow the same chain, with batch numbers, process loss and yield in place of serial numbers.
Planning
Know what you can promise.
Stock on the shelf is only half the answer. BeatOS ERP works out projected stock: what you have, plus what is coming, minus what is already spoken for.
- Projected stock for every item and warehouse
- Reorder level and safety stock that raise requests by themselves
- Production and purchase planned together for many orders at once
- Sales sees the same availability before promising a date
Copper winding wire 1.2 mmMain stores · sample data
In stock840 kg
+ On purchase order500 kg
+ Requested, not yet ordered0 kg
− Reserved for sales orders300 kg
− Reserved for work orders700 kg
Projected stock340 kg
ReorderBelow the reorder level of 400 kg. A material request for 600 kg has been raised.
Quality
A check at every gate.
Mark an item as needing inspection, and nothing moves past that point until it is checked and recorded.
Incoming
Raw material checked on receipt against its template, with sample size and readings.
- Accept or reject by lot
- Rejects kept in a separate store
- Supplier quality history
In process
Checks between operations, so a fault is caught before more value is added.
- Readings at the workstation
- Linked to the job card
- Rework recorded
Final and outgoing
Finished goods tested before they enter stock or leave with a delivery.
- Pass, fail and retest
- Certificate data per batch
- Random checks on dispatch
Traceability
Every batch and serial number traced from the supplier's lot to the customer's invoice.
- Trace forward and back
- Batch-wise stock history
- Complaints linked to the batch
Reports
See what is late, short and costing more.
Every report reads the records the shop floor writes, so it is current without anyone compiling it.
Production planningWhat to make and buy, and when
Work order summaryOpen, late and completed orders
Job card summaryTime by operation and operator
Production analyticsOutput over weeks and months
BOM stock reportCan we make it with today's stock?
BOM cost and variancePlanned vs actual cost per unit
Downtime analysisMachine time lost, and why
Quality inspection summaryPass and reject rates by item
Stock ledgerEvery movement, every warehouse
Batch-wise balance historyOne batch, from receipt to dispatch
Projected stockOrdered, reserved and planned
Job work stockMaterial lying with job workers
BeatOS ERP for manufacturers
Production, stock and money, in one ERP.
The factory, the stores and the accounts work on the same orders the sales team books.
Production and BOMs
Multi-level BOMs, production plans from sales orders, work orders and job cards.
- MRP from orders
- Shop-floor job cards
- Subcontracting
Stores and batches
Raw material, WIP and finished goods by godown, batch and serial number.
- Reorder levels
- Batch traceability
- Quality on receipt
Purchase
Material requests from the plan, supplier quotes, approved orders and receipts.
- Short items flagged
- Quotes compared
- Bills matched
Costing, GST and accounts
Cost per unit, GST invoices with e-way bills, and books updated as you dispatch.
- Planned vs actual cost
- E-invoice and e-way bill
- Receivables ageing
Sales and service
The field team works on the same records.
Dealer visits, product trials and service calls happen in the BeatOS app, and land on the same orders, items and serial numbers the factory uses.
- 1. Dealer visitBeat plan, GPS check-inBeatOS app · Visits & Beats
- 2. Product trialReadings and result on siteBeatOS app · Trials
- 3. QuotationMade from the passed trialBeatOS ERP · Quotation
- 4. Order to productionStock checked, work order plannedBeatOS ERP · Work Order
- 5. Dispatch and invoiceGST invoice, e-way billBeatOS ERP · Sales Invoice
- 6. Service visitComplaint closed with a causeBeatOS app · Complaints
Challenges and solution
Where manufacturers lose time, and what changes.
Read it left to right: the problems we hear most, what we set up in BeatOS ERP, and what your field team gets.
1The challenge
Where time is lost today
- Production is planned on spreadsheets that are out of date by noon.
- Material runs short, or is bought twice, because nobody sees what is reserved.
- The real cost of a product is a guess.
- Sales promises dates without sight of stock or production.
- Quality records live on paper and cannot be traced to a batch.
2We set up BeatOS ERP
One record for the whole factory
- Items, workstations and operations
- Multi-level bills of materials
- Production planning and work orders
- Job cards and job work
- Quality inspection templates
- Stock by warehouse, batch and serial
- Purchase, GST invoicing and accounts
3BeatOS adds in the field
What your team does on the phone
- Beats and dealer visits, with GPS proof.
- Orders that check the same stock the planner sees.
- Product trials with test results.
- Service and complaint visits found by serial number.
- Targets and expenses for the sales team.
The resultEvery order traced from the dealer visit, through the shop floor, to the service call.
The apps
What manufacturing teams use most.
Start with the apps that fix your biggest problem, and switch on more later. Click an app to see it in detail.
Specialised setups
Ready-made for parts of manufacturing.
We have deeper setups for these trades, with their own forms, reports and workflows.
How we implement
From first study to ongoing support.
Six steps, run by the BeatOS team with yours. We start by walking one product through your factory, then set up the records above around it.
- 1StudyWalk one product through your factory and agree the scopeERP Implementation
- 2ConfigureBOMs, workstations and plans on your own dataERP Implementation
- 3MigrateMove and check items, stock and balancesData Migration
- 4TrainPlanners, stores, shop floor and accountsTraining
- 5Go liveWith our team alongside yoursERP Implementation
- 6SupportOngoing help, changes and updatesSupport & Hosting
FAQ
From manufacturing teams
Your process is different?
Tell us how one product moves through your factory, and we will show it running in BeatOS ERP.
Book a demo →Which kinds of manufacturing does BeatOS ERP support?
Make to stock, make to order, engineer to order, discrete assembly, batch, process and repetitive production. Most factories mix a few, and each product line is set up the way it is actually made.
Can we have sub-assemblies with their own BOMs?
Yes. Multi-level BOMs let a sub-assembly have its own BOM and work order, and the production plan works out every level for you.
Can we plan production and purchase for many orders at once?
Yes. A production plan pulls in open sales orders or a forecast for a period, then creates the work orders and material requests for everything that is short.
Do you handle job work with outside suppliers?
Yes. Material sent to a job worker is tracked at their end, and the finished goods are received against a subcontracting order with the service charge billed.
How do we know the real cost of a product?
From the BOM: materials at your chosen rate, operation time at each workstation's hourly cost, and any overheads. Actual cost from each work order is compared with the plan.
Can sales see stock and production before promising a date?
Yes. Sales orders, projected stock and work orders are in the same BeatOS ERP, so the rep and the office see the same availability.
Do you handle product trials and test results?
Yes. Trials are planned, run and approved in BeatOS, with readings and results, and a passed trial becomes a quotation.
We already run production in another ERP. Can we add BeatOS?
Yes. If it is compatible, BeatOS installs on your existing site and works on your customers, items and stock. If not, we move your data into BeatOS ERP.
Related industries
Also configured for teams like yours.
See your factory running on BeatOS ERP.
Bring one product and its BOM. We will show it planned, made, checked and costed.