Prevent raw material shortages, automate component demand forecasting, and schedule procurement in sync with production jobs.
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Listen to our supply chain architect explain how MRP calculates component requirements against sales orders and safety stock.
Audio Summary: This briefing presents how ERPPWA Material Requirements Planning (MRP) aligns sales forecasts and firm orders with inventory levels and production timelines to prevent raw material stockouts.
Key Topics Covered:
Eliminate component shortages, synchronize master production schedules, and track raw material heat numbers across the entire supply chain.
Stockouts cause assembly lines to stall while excess slow-moving inventory drains cash flow; manual stock cards fail to provide multi-location visibility or timely reorder alerts.
Eliminate stockouts with automated replenishment rules. ERPPWA monitors stock levels in real-time across multiple godowns and shop floors, triggering automated reorder rules based on minimum safety stock and supplier lead times.
Prevent costly production stoppages and minimize holding capital with automated reorder rules and multi-godown stock synchronization.
Get in Touch| Item Code | Description | Location | On-Hand | Reorder Level | Action Status |
|---|---|---|---|---|---|
| RM-STL-316 | SS 316 Hex Bar 25mm | Raw Stores A-2 | 420 kg | 600 kg | ⏳ Reorder Triggered |
| RM-ALU-6061 | Alloy Plate 12mm | Raw Stores B-1 | 1,850 kg | 1,000 kg | ✓ Sufficient Stock |
| FD-BOLT-M10 | High Tensile M10 Bolt | Hardware Bin 04 | 150 pcs | 500 pcs | ● Critical Shortage |
Conflicting customer delivery dates, unmonitored machine downtime, and ad-hoc job routing cause chronic production bottlenecks and missed dispatch deadlines.
Maximize shop floor output with intelligent scheduling. Visual finite-capacity scheduling allocates machines, tooling, materials, and operator labor with real-time Gantt tracking, dynamic job re-sequencing, and setup optimization.
Maximize machine utilization and guarantee on-time job completion with intelligent finite-capacity scheduling and live dispatch routing.
Get in Touch| Job Card # | Work Center | Target Component | Planned Time | Capacity Load | Run Status |
|---|---|---|---|---|---|
| JC-8820 | VMC-01 (Haas 5-Axis) | Valve Housing Body | 08:00 - 14:30 | ✓ 92% Utilized | Running |
| JC-8824 | CNC Lathe #03 | Turbine Shaft OD 60 | 14:30 - 20:00 | ✓ 88% Utilized | Queued |
| JC-8829 | EDM Wirecut #02 | Hardened Die Insert | 20:00 - 04:00 | ⏳ Tooling Setup | Tooling Set |
Working capital stays trapped in dead stock because procurement buys in bulk based on intuition rather than historical sales velocity and seasonal demand trends.
Free up cash flow with demand-driven replenishment. A centralized cloud database forecasts material consumption using historical trends, calculates optimal order quantities (EOQ), and eliminates dead stock accumulation.
Liberate tied-up operating capital and optimize warehouse square-footage with data-driven inventory forecasting and EOQ analytics.
Get in Touch| Material Category | Total Value | Turnover Ratio | Forecast Trend | Inventory Status |
|---|---|---|---|---|
| Carbon Steel Flanges | ₹24.5 Lakhs | 8.4x / year | ✓ High Velocity (+18%) | Optimized |
| Hydraulic Valves | ₹16.2 Lakhs | 6.2x / year | ✓ Steady Velocity | Balanced |
| Special Fasteners | ₹4.8 Lakhs | 1.1x / year | ⏳ Slow Moving | Cap Reorders |
Fragmented communication between purchasing, sub-contractors, transporters, and receiving docks causes delayed raw material deliveries and uncontrolled freight costs.
Synchronize your supply chain from supplier to customer dock. ERPPWA integrates all 6 supply chain pillars—Planning, Procurement, Manufacturing, Warehouse, Order Fulfillment, and Logistics—into one synchronized control tower.
Control costs and secure reliable lead times with an integrated supply chain ecosystem connecting suppliers, sub-contractors, and freight carriers.
Get in Touch| Consignment # | Supplier / Job Worker | Commodity | ETA / Milestone | Transit Status |
|---|---|---|---|---|
| TRK-7712 | Jindal Steel & Power | 30 Tons HR Coils | ETA: Today 18:00 | ✓ On Schedule |
| JW-4109 | Om Precision Heat Treat | 500 pcs Gear Blanks | ETA: Tomorrow 11:00 | ✓ Heat Treating |
| TRK-7718 | TCI Freight Logistics | Electric Motors & Drives | Delayed by 4 Hours | ⏳ Highway Delay |
Production planners spend hours manually exploding complex multi-level BOMs in Excel, making calculation errors that result in missing fasteners or plates during assembly.
Automate multi-level shortage calculations in seconds. Automated multi-level BOM explosion instantly calculates net raw material shortages by deducting live on-hand stock, incoming POs, and reserved WIP buffers.
Eliminate manual calculation errors with instant BOM explosion and automated purchase requisitions for exact net shortages.
Get in Touch| Part Number | Description | Gross Req. | Free Stock | Net Shortage | Action Status |
|---|---|---|---|---|---|
| GB-PIN-04 | Hardened Sun Pinion 20T | 25 pcs | 30 pcs | 0 pcs | ✓ Stock Available |
| BRG-SKF-6208 | Deep Groove Ball Bearing | 50 pcs | 12 pcs | 38 pcs | ● Auto-PR Raised |
| CS-HSG-50 | Cast Iron Housing Body | 25 pcs | 5 pcs (20 PO) | 0 pcs | ✓ Inward Today |
Shop floor workers pull raw materials without proper records, resulting in stock discrepancies, lost offcuts, and failed customer quality audits due to missing heat numbers.
Enforce full metallurgical lineage from stores to dispatch. Strict Material Issue Vouchers (MIV) verify barcode scans against approved job cards, enforce full Heat Number/MTC traceability, and track scrap returns accurately.
Ensure end-to-end metallurgical traceability and zero inventory leakage with barcode-controlled shop floor material issue vouchers.
Get in Touch| MIV Slip # | Heat / Lot # | Material Grade | Issued Qty | Operator / Station | Verification |
|---|---|---|---|---|---|
| MIV-3301 | HT-2026-X992 | EN24 Quenched Bar 50mm | 180 kg | R. Sharma / VMC-01 | ✓ Barcode Pass |
| MIV-3304 | HT-2026-B410 | SS 304 Seamless Pipe 2" | 65 m | M. Solanki / Saw-02 | ✓ MTC Attached |
| MIV-3308 | HT-2026-A104 | Alloy Steel Forging Blank | 40 pcs | K. Parmar / Lathe-01 | ✓ Verified |
Every manufacturing process has unique scrap allowances, lead-time rules, and material specifications. Our ERP is fully customized to adapt MRP demand calculators, BOM layouts, and purchase requisition workflows to your operations.
Request CustomizationDeploy ERPPWA on your factory floor server for complete offline autonomy and data isolation, or host on private cloud for instant multi-plant coordination.
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