# ERP for Manufacturers: Production, Quality, Costing | BeatOS > Manufacturing ERP for factories in India and worldwide: multi-level BOMs, production planning, job cards, job work, quality checks and cost per unit, with GST and accounts. URL: https://beatoserp.com/beatos/industries/manufacturing [Home](https://beatoserp.com/beatos) / [Industries](https://beatoserp.com/beatos/industries) / Manufacturing 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. [Book a demo for manufacturing](https://beatoserp.com/beatos#demo) See one order, end to end - Discrete, batch and process - Planned from sales orders - Cost per unit, not a guess Production plan · SO-2291 Live Sample data 200 Pumps ordered 3 Work orders 2 Items short ₹6,840 Cost / pump WO Motor assembly × 200 Sub-assembly · winding line · 64% done Running MR Copper winding wire 1.2 mm Projected 340 kg · reorder at 400 kg Ordered JW Casting machining · job work 180 of 200 back from Sai Engineering At supplier QI Final test · lot 11/26 Pressure and current within limits Passed Types 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 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 ### 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 →](https://beatoserp.com/beatos/services/erp-implementation) 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. - Items Raw materials, sub-assemblies, finished goods and services, with units and HSN codes. - Workstations Machines and lines, with their hourly cost, working hours and how many jobs they run at once. - Operations Each step of the work, such as winding, machining or testing, done at a workstation. - Bills of materials What goes into a product and which operations make it, with sub-assemblies having their own BOMs. - Work orders An instruction to make a quantity from a BOM. It reserves the material and lists the operations. - Job cards One per operation on the shop floor, with time logged by operator and machine. Multi-level BOM v3 Sample data - Submersible pump 1 HP Finished good × 1 - Motor assembly Sub-assembly own BOM - Stator stampings Raw material 3.2 kg - Copper winding wire Raw material 1.4 kg - Rotor shaft Raw material × 1 - Pump body, machined Job work from casting - Impellers Raw material × 6 - Cable, gland and packing Raw material 1 set Operations: Winding Varnishing Assembly Pressure test Packing 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 01 Sales order A dealer orders 200 pumps for the 30th, from the office or the rep's phone. Sales order Sales 02 Production plan The plan opens the multi-level BOM and works out the motors to make and the material to buy. Production plan Planner 03 Material requests Anything short after counting stock, orders and reservations goes to purchase. Material request Planner ### Buy and receive 04 Purchase and receipt Copper wire is ordered with approval and received with an incoming check; rejects go to a separate store. Purchase order Receipt Purchase, stores 05 Job work Castings go to a machining job worker; their stock is tracked until the bodies come back. Subcontracting order Purchase 06 Issue to the shop floor Material for each work order moves from stores to work in progress. Stock entry Stores ### Make and check 07 Motor work order Motors are wound and varnished first, as a sub-assembly with its own work order. Work order Production 08 Job cards Each operation is logged at its workstation, with time and operator, so delays show the same day. Job card Operators 09 Final assembly and test Pumps are assembled, then pressure-tested against limits before they are accepted. Quality inspection Quality ### Ship and close 10 Finished goods Each pump enters stock with its own serial number, for warranty and service later. Stock entry Stores 11 Dispatch and invoice Delivery note, GST e-invoice and e-way bill go out together. Delivery note Invoice Dispatch, accounts 12 Cost and service Actual cost per pump is compared with the plan; service visits later find the pump by serial. Costing Accounts, 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 mm Main stores · sample data In stock 840 kg + On purchase order 500 kg + Requested, not yet ordered 0 kg − Reserved for sales orders 300 kg − Reserved for work orders 700 kg Projected stock 340 kg Reorder Below 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 planning What to make and buy, and when Work order summary Open, late and completed orders Job card summary Time by operation and operator Production analytics Output over weeks and months BOM stock report Can we make it with today's stock? BOM cost and variance Planned vs actual cost per unit Downtime analysis Machine time lost, and why Quality inspection summary Pass and reject rates by item Stock ledger Every movement, every warehouse Batch-wise balance history One batch, from receipt to dispatch Projected stock Ordered, reserved and planned Job work stock Material 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 [Explore →](https://beatoserp.com/beatos/erp/manufacturing) ### Stores and batches Raw material, WIP and finished goods by godown, batch and serial number. - Reorder levels - Batch traceability - Quality on receipt [Explore →](https://beatoserp.com/beatos/erp/stock) ### Purchase Material requests from the plan, supplier quotes, approved orders and receipts. - Short items flagged - Quotes compared - Bills matched [Explore →](https://beatoserp.com/beatos/erp/buying) ### 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 [Explore →](https://beatoserp.com/beatos/erp/accounts) [See every module of BeatOS ERP →](https://beatoserp.com/beatos/erp) 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. In the field · BeatOS app In the office · BeatOS ERP The same record moves through every step, so nobody types it twice. - 1. Dealer visit Beat plan, GPS check-in BeatOS app · Visits & Beats - 2. Product trial Readings and result on site BeatOS app · Trials - 3. Quotation Made from the passed trial BeatOS ERP · Quotation - 4. Order to production Stock checked, work order planned BeatOS ERP · Work Order - 5. Dispatch and invoice GST invoice, e-way bill BeatOS ERP · Sales Invoice - 6. Service visit Complaint closed with a cause BeatOS 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. 1 The 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. 2 We 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 3 BeatOS 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 result Every 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. [Construction chemicalsTrials at batching plants, cube tests, trial to orderSee the specialised setup →](https://beatoserp.com/beatos/industries/construction-chemicals)[Industrial B2BDemos, service SLAs and key accountsSee the specialised setup →](https://beatoserp.com/beatos/industries/industrial-b2b) 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. Before go-live After go-live - 1 [StudyWalk one product through your factory and agree the scopeERP Implementation](https://beatoserp.com/beatos/services/erp-implementation) - 2 [ConfigureBOMs, workstations and plans on your own dataERP Implementation](https://beatoserp.com/beatos/services/erp-implementation) - 3 [MigrateMove and check items, stock and balancesData Migration](https://beatoserp.com/beatos/services/data-migration) - 4 [TrainPlanners, stores, shop floor and accountsTraining](https://beatoserp.com/beatos/services/training) - 5 [Go liveWith our team alongside yoursERP Implementation](https://beatoserp.com/beatos/services/erp-implementation) - 6 [SupportOngoing help, changes and updatesSupport & Hosting](https://beatoserp.com/beatos/services/support-hosting) FAQ ## From manufacturing teams Tell us how one product moves through your factory, and we will show it running in BeatOS ERP. [Book a demo →](https://beatoserp.com/beatos#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. [Book a demo](https://beatoserp.com/beatos#demo)[Manufacturing ERP in detail](https://beatoserp.com/beatos/erp/manufacturing)