Can ERPPWA automatically identify raw material shortages before starting a job?

Yes. When a Job is scheduled, ERPPWA generates a 'Required to Purchase Stock List' comparing BOM requirements against current free stock. It calculates the exact shortfall and creates Job-Wise Purchase Orders with pre-scheduled delivery dates.

Manufacturing ERP & Production Management Software | BOM & Job Cards

Q: Does ERPPWA support multi-level Bills of Materials (BOM)?

Yes. ERPPWA supports multi-level, nested Bills of Materials (BOM) for complex assemblies, sub-assemblies, semi-finished components, and raw materials. It accounts for scrap percentages, operational process sequences, and estimated unit production costs.

Q: How does ERPPWA track jobs across different shop-floor departments and machines?

ERPPWA generates Job Cards per employee, department, and process. Supervisors can monitor the live Job Tracking by Department dashboard to see which work orders are at cutting, machining, heat treatment, or final assembly with real-time percentage completion.

Q: Can we track raw material serial numbers embedded inside the finished product?

Yes. ERPPWA records the specific raw material heat codes, batch numbers, and component serial numbers used in each master finished product, ensuring full cradle-to-grave traceability for warranty audits.

Q: How does ERPPWA handle subcontractor and contractor job work?

ERPPWA manages outside processes with dedicated contractor Delivery Notes. It tracks sent materials, returned finished components, allowable process shrinkage, and contractor service billing with automatic reconciliation.

Q: Does ERPPWA include Quality Control (QC) inspection templates?

Yes. ERPPWA provides standardized QC Templates for inward raw materials, in-process stage inspection, and pre-dispatch final inspection. Rejected items can be routed into dedicated Rework Jobs or scrapped.

Q: How does ERPPWA identify and alert on production delays?

ERPPWA includes three predictive delay analytics reports: Job Intime Report, Job Possible Delay Report, and Job Delay Report. Supervisors receive automated alerts before milestone delivery dates breach.

Q: Can we record scrap and scrap sales income by job?

Yes. ERPPWA records generated scrap by job and logs scrap sales revenue directly against job ledger accounts, giving owners an accurate picture of net manufacturing yields and scrap recovery.

Q: Can we print Job BOMs with operational processes for factory floor workers?

Yes. ERPPWA generates printable Job BOM documents detailing raw materials, component drawing references, cutting sizes, and process steps for shop floor operators.

⚡ Operational Capabilities

End-to-End Manufacturing & Shop-Floor Features

Explore how ERPPWA eliminates production delays, automates material staging, and enforces actual batch costing.

📑 Multi-Level BOM ⚙️ Process Routing Templates 🖨️ Print Job BOM

Multi-Level Bill of Materials (BOM) & Process Templates

⚠️ The Operational Challenge

Complex manufactured assemblies consist of dozens of sub-assemblies, raw metals, hardware fasteners, and outside heat treatments. Managing BOMs on spreadsheets leads to missing components, unexpected shop-floor stoppages, and inaccurate pre-order cost estimations.

✨ The ERPPWA Solution

Formulate nested, multi-level Bills of Materials (BOM) with complete operational process routing. Define raw materials, sub-assemblies, scrap percentages, and process sequences (Cutting → Machining → Heat Treatment → Assembly). Print comprehensive Job BOMs with drawings and routing notes in 1 click.

✓Multi-level nested BOM hierarchy for complex assemblies & parts
✓Process routing templates mapping sequences, runtimes & machines
✓Print Job BOM with processes and cutting specifications for workers
✓Component scrap percentage allowances and recovery factor calculations
✓Pre-production standard cost estimation vs. actual cost comparisons
✓1-Click duplicate & clone BOM tool to quickly spin off product variants

Standardize manufacturing blueprints and ensure 100% component availability before production starts.

Schedule Guided Demo →

Bill of Materials & Routing • Live UI

📑 BOM Explosion: Hydraulic Cylinder 80mm

● BOM VERIFIED (REV 3)

14 Parts

Components in BOM

5 Stages

Process Routing

₹ 3,420

Est. Unit Cost

Component / Part	Qty Required	Scrap %	Stage / Process
SS316 Seamless Tube	1.25 Meters	2.5%	CNC Turning • M-01
Piston Rod (En8D Hardened)	1.00 Pcs	0.0%	Hard Chrome • Outside
Hydraulic Seal Kit (Viton)	1.00 Set	0.0%	Final Assembly Line

🖨️ Shop-Floor Handover 1-Click Print Job BOM with complete technical drawings attached

📋 Digital Job Cards 📍 Department-Wise Progress 👷 Employee Work Logs

Production Jobs, Job Cards & Department Tracking

⚠️ The Operational Challenge

When a customer calls asking about their order status, factory supervisors run across machining, grinding, and fabrication shops with clipboards asking: "Where is this job right now?" Paper job cards get soiled, lost, or back-dated by operators.

✨ The ERPPWA Solution

Gain live real-time visibility across all shop-floor stages with Job Tracking by Department. ERPPWA issues digital Job Cards per employee and process. Operators scan job cards, log machine runtime hours, and record completed parts, updating management dashboards instantaneously.

✓Individual digital and printable Job Cards per employee and process
✓Live Job Tracking by Department (Cutting, Turning, Welding, Assembly)
✓Real-time percentage progress tracking on every active work order
✓Logged operator labor hours linked directly to job cost ledgers
✓'My Jobs' mobile view for floor supervisors and line managers
✓Eliminates shop-floor confusion and stops operators picking wrong jobs

Answer customer dispatch inquiries in 5 seconds without leaving your desk.

Schedule Guided Demo →

Department Job Tracker • Live UI

📍 Job Tracking by Department

● 18 ACTIVE JOBS

Job No / Product	Current Department	Assigned Operator	Stage Progress
JOB-2026-088 Hydraulic Cylinder 80mm	CNC Machining • Bay 2	Rajesh K. (Lathe 04)	75% • IN-PROGRESS
JOB-2026-092 SS316 Flanges (250 Pcs)	Outside Contractor	Apex Hard Chrome	DELIVERY NOTE #42
JOB-2026-094 Shaft Coupling Sets	Quality Control (PDI)	Vikas M. (QC Lead)	95% • FINAL INSPECT

92.4%

On-Time Stage Execution

0 Paper Loss

Digital Barcode Job Cards

📊 Required to Purchase List ⚡ Job-Wise Purchase Orders 📅 Scheduled Long-Term Buying

Smart Job-Wise Material Planning & Shortage Auto-PO

⚠️ The Operational Challenge

Production begins on a high-value order, only for the assembly line to grind to an emergency halt on Day 4 because a specific bronze bushing or O-ring was out of stock. Purchasing buys at 30% premium market rates, eroding job margins.

✨ The ERPPWA Solution

Never suffer material shortages during production. When a job is released, ERPPWA calculates the 'Required to Purchase Stock List' comparing BOM needs against unreserved warehouse stock. Generate Job-Wise Purchase Orders in 1 click and schedule phased deliveries for long-term production contracts.

✓Automated 'Required to Purchase Stock List' calculation per job
✓Job-wise Purchase Orders (PO) linked directly to the parent work order
✓Job-wise Goods Received Notes (GRN) automatically tagging received items
✓Scheduled phased raw material purchasing for multi-month projects
✓Prevents over-purchasing and frees up working capital from dead stock
✓Full audit visibility: see which PO supplied materials to which finished job

Ensure 100% material staging before releasing jobs to the shop floor.

Schedule Guided Demo →

Material Shortage & Auto-PO • Live UI

📊 Required to Purchase: JOB-2026-088

● 2 ITEMS SHORT

Raw Material / Part	Job Need	Free Stock	Shortage & Action
SS316 Seamless Tube	120 Meters	150 Meters	✓ IN-STOCK (RESERVED)
En8D Piston Rod 40mm	80 Meters	20 Meters	⚡ 1-Click PO: 60 Mtr
Viton Hydraulic Seals	100 Sets	40 Sets	⚡ 1-Click PO: 60 Sets

📅 Phased Purchasing Scheduled Delivery: Batch 1 on 10-Oct • Batch 2 on 24-Oct

📦 Material Issued to Production 🔢 Raw Material Serial Tagging 🛡️ Cradle-to-Grave Trace

Material Issued to Production & Serial Traceability

⚠️ The Operational Challenge

When raw materials leave warehouse shelves, storekeepers deduct inventory on paper slips without recording which serial numbers or heat batches went into which finished machines. During ISO or customer quality audits, proving component origins takes weeks of manual digging.

✨ The ERPPWA Solution

Enforce 100% material accountability with digital Material Issue slips. ERPPWA deducts store stock and transfers inventory directly into shop-floor Work-in-Progress (WIP). Record raw material serial numbers and supplier heat codes embedded inside each master product for instant backward trace.

✓1-Click Material Issue against authorized jobs and BOM quantities
✓Real-time Work-in-Progress (WIP) valuation and shop-floor balance tracking
✓Embedded component serial number recording inside master product records
✓Material return voucher for returning excess unused raw stock back to store
✓Prevents unauthorized consumption or unmonitored material diversions
✓Cradle-to-grave audit certificate ready for Tier-1 defense and OEM audits

Pass rigorous customer quality audits with push-button component genealogy.

Schedule Guided Demo →

Material Issue & Genealogy • Live UI

📦 Material Issue Slip: MIP-2026-042

● ISSUED TO JOB #088

Material Issued	Heat / Batch No	Quantity	Master Product Serial
SS316 Forged Cylinder Body	HEAT-8812-JINDAL	25 Pcs	SN-HYD-2026-001 to 025
Hardened Piston Rods	BATCH-CHROME-412	25 Pcs	TAGGED TO ASSEMBLY
High-Pressure Seals	LOT-VT-9902	25 Sets	✓ QC VERIFIED

🔍 Component Traceability When SN-HYD-001 is queried → Heat code JINDAL-8812 identified in 1s

🚚 Subcontractor Job Work 📑 Contractor Delivery Notes ⚖️ Scrap & Shrinkage Audit

Subcontractor & Contractor Job Work Management

⚠️ The Operational Challenge

Sending semi-finished goods for outside electroplating, galvanizing, or precision grinding creates huge inventory blindspots. Dispatched quantities don't match returned items, scrap is undocumented, and contractor labor bills are paid without physical verification.

✨ The ERPPWA Solution

Master outside job work with process-wise Delivery Notes. Generate official subcontracting gate-passes specifying operations (e.g. Chrome Plating). Track goods sent, goods received back, process shrinkage percentages, and approve contractor labor billing automatically against received quantities.

✓Process-wise Delivery Notes for goods sent to external job workers
✓Job-wise goods received note (GRN) from contractors with QC checks
✓Allowable process shrinkage & contractor scrap reconciliation
✓Contractor labor voucher generation linked directly to PO rate contracts
✓Pending contractor stock report showing parts sitting at external vendors
✓Statutory GST Job Work delivery challan (ITC-04) compliance ready

Eliminate vendor inventory leaks and verify contractor invoices with zero disputes.

Schedule Guided Demo →

Subcontractor Job Work • Live UI

🚚 Contractor Delivery Notes & Receipts

● SUBCONTRACTING ACTIVE

Delivery Note / Vendor	Outside Process	Qty Sent → Recd	Scrap / Status
DN-CONT-2026-081 Apex Hard Chrome Ltd	Hard Chrome Plating (50 Micron)	80 Pcs → 80 Pcs	✓ QC PASSED (100%)
DN-CONT-2026-082 Shree Ganesh Heat Treat	Induction Hardening HRC 58	200 Pcs → 196 Pcs	4 Pcs Scrap (2% Norm)
DN-CONT-2026-083 Pooja Grinding Works	Centerless Cylindrical Grind	150 Pcs → Pending	AT CONTRACTOR (DUE 2D)

📑 1-Click Billing Approved 80 Pcs Chrome Plating → 1-Click convert to Contractor Bill

💰 Actual Production Costing 📈 True Gross Margin Realization 🔍 Variance Analysis

Actual Production Costing: Materials + Labor + Overhead

⚠️ The Operational Challenge

Manufacturers quote prices based on standard BOM estimates, but real production incurs machine electricity spikes, operator overtime, tool wear, and scrap rejections. Factory owners only discover months later that high-volume jobs actually lost money.

✨ The ERPPWA Solution

Calculate true landed production costs with mathematical precision. ERPPWA applies the exact formula: Used Materials + Process Expenses + Direct Labor = Actual Production Cost. Gain live variance reports comparing standard estimates to actual batch cost, protecting net profitability.

✓Formula: Used Materials + Process Expenses + Labor = Actual Cost
✓Live variance tracking between estimated BOM cost and real batch cost
✓Direct operator labor cost absorption based on logged Job Card hours
✓Machine electricity, tooling & outside contractor expense allocation
✓Finished goods unit inventory valuation updated at true actual cost
✓Batch profitability reports identifying high-margin vs loss-making jobs

Price your products with scientific confidence and eliminate hidden factory margin erosion.

Schedule Guided Demo →

Actual Costing Console • Live UI

💰 Actual Production Cost: JOB-2026-088

● BATCH COMPLETED

₹ 1,72,500

Raw Materials Used

₹ 48,200

Labor (64 Hours)

₹ 26,400

Overhead / Subcontract

Cost Element	BOM Estimate	Actual Incurred	Variance & Impact
Raw Materials (Alloy Steel)	₹ 1,68,000	₹ 1,72,500	+2.6% (Metal Spike)
Direct Machinist Labor	₹ 52,000	₹ 48,200	-7.3% (Ahead of Sched)
Chrome Plating & Power	₹ 25,000	₹ 26,400	+5.6% (Freight)

🎯 Real Batch Profitability Actual Unit Cost: ₹ 3,294 / pc • Realized Gross Margin: 32.1%

🔍 Standardized QC Templates 🔄 Job-Wise Rework Management 💵 Scrap Sales Income Tracking

Quality Control (QC), Rework & Scrap Accounting

⚠️ The Operational Challenge

Quality checks performed verbally without standardized inspection templates result in defective goods slipping through to clients. Reworked parts incur unrecorded operator labor, and scrap metals are sold for cash without accounting entries or recovery tracking.

✨ The ERPPWA Solution

Institutionalize zero-defect manufacturing discipline. ERPPWA provides standardized QC Templates for inward receiving, in-process stages, and final pre-dispatch inspection (PDI). Track job-wise rework cycles with separate labor tracking, and record scrap generation alongside scrap sales income.

✓Configurable QC Templates with dimensional tolerances & testing criteria
✓Inspection stages: Inward raw material, In-process stage, and Final PDI
✓Dedicated Rework Jobs with labor logging and root-cause analysis
✓Record scrap generation weight by job and allocate scrap recovery incomes
✓Prevents dispatch of uninspected goods or pending QC clearance items
✓Print official Quality Inspection Certificates (EN 10204 3.1) in 1 click

Protect your brand reputation and recover hidden profits from systematic scrap control.

Schedule Guided Demo →

Quality & Scrap Console • Live UI

🔍 QC Inspection: Hyd Cylinder 80mm

● INSPECTION PASSED

Inspection Parameter	Spec Tolerance	Observed Value	QC Result
Bore Diameter (ID)	80.00 ± 0.02 mm	80.012 mm	✓ WITHIN TOLERANCE
Chrome Layer Thickness	Min 35 μm	42 μm	✓ PASSED
Hydrostatic Pressure Test	250 Bar (15 Mins)	252 Bar • 0 Leak	CERTIFIED 3.1

💵 Scrap Recovery Ledger 14 KGs Turnings Scrapped • ₹ 560 Scrap Income Credited to Job #088

🚨 Predictive Delay Intelligence ⏱️ Job Intime / Delay Reports 🛠️ Machine Management

Machine Management & Predictive Delay Intelligence

⚠️ The Operational Challenge

Machine breakdowns, tooling bottlenecks, and unmonitored stage delays cause promised customer delivery dates to breach. Factory owners and sales reps only find out a shipment is late on the promised dispatch day itself, damaging buyer trust and triggering penalties.

✨ The ERPPWA Solution

Eliminate surprise delays with predictive shop-floor intelligence. ERPPWA includes Machine Management and three proactive tracking reports: Job Intime Report, Job Possible Delay Report, and Job Delay Report. Identify bottlenecks 3 to 5 days in advance and reallocate machine loads proactively.

✓Predictive Job Possible Delay Report alerting on emerging bottlenecks
✓Job Intime Report celebrating on-schedule completion and operator speed
✓Root-cause delay analysis: Material shortage, Machine downtime, Subcontractor
✓Machine Management: runtime logging, planned maintenance, and utilization
✓1-Click Finished Goods Inward transferring completed jobs to store inventory
✓Executive production dashboard with overall plant OEE and dispatch timelines

Achieve 98%+ on-time delivery rates and delight high-value enterprise buyers.

Schedule Guided Demo →

Machine & Delay Monitor • Live UI

🚨 Predictive Delay Intelligence

● DISPATCH GUARANTEE

Job No / Customer	Promised Date	Current Stage	Predictive Risk Status
JOB-2026-088 Bharat Heavy Machineries	12-Oct-2026	Assembly Line 01	✓ INTIME (1.5d Ahead)
JOB-2026-092 Shreeji Auto Components	14-Oct-2026	Outside Chrome Plating	⚠️ POSSIBLE DELAY (12h Risk)
JOB-2026-095 Apex Tooling Solutions	08-Oct-2026	Finished Goods Store	✓ COMPLETED • INWARDED

⚡ Proactive Action Trigger JOB-092 flagged: Expedite contractor follow-up to preserve 14-Oct dispatch

🛠️ Tailor-Made Guarantee

100% Free Customization

Every manufacturing enterprise has distinct routing hierarchies, Job Card print layouts, and machine overhead formulas. With ERPPWA, our software adapts to your proven shop-floor operations—not the other way around. We charge ₹0 for tailoring the Production module to your operations.

✓Custom Job Card formats, barcode stickers & job travelers print layouts
✓Specialized multi-stage stage approval chains and scrap tolerance rules
✓Tailored machine electricity & overhead cost allocation formulas

🏢 Deployment Freedom

Private Cloud or 100% On-Premise

Enjoy complete architectural sovereignty. Host ERPPWA on our managed encrypted cloud for effortless multi-plant access, or deploy it 100% On-Premise on your local factory server for total data privacy and zero internet downtime dependency on your shop floor.

✓Encrypted Cloud with 99.99% uptime and automatic backups
✓100% On-Premise deployment on your factory LAN server
✓Native Progressive Web App (PWA) works seamlessly on shop-floor tablets

Manufacturing Capability	ERPPWA Intelligent Platform	Traditional Legacy Other ERPs
Multi-Level BOM & Process Routing	✅ Nested multi-level BOMs with scrap % & 1-click printable process sheets	❌ Rigid single-level BOMs or complex engineering add-on modules
Digital Job Cards & Department Tracking	✅ Live Department Job Tracker with operator work hours & mobile scan	❌ Paper clipboards and retroactive manual data entry
Job-Wise Shortage Calculation & Auto-PO	✅ Automated 'Required to Purchase Stock List' with 1-click PO generation	❌ Disconnected purchasing; frequent line-stopping material shortages
Serial Component Genealogy	✅ Embedded raw material serial and heat codes traced in master product	❌ Incomplete traceability; cannot isolate defective vendor batches
Subcontractor Delivery Notes & Scrap	✅ Process-wise outside delivery notes, shrinkage norms & labor billing	❌ Manual delivery challans with high unrecorded contractor scrap
Actual Landed Unit Costing	✅ Scientific formula: Used Materials + Process Expenses + Direct Labor	❌ Standard cost estimates only; hidden overhead costs eat profits
Quality Inspection & Rework Management	✅ Standardized QC Templates (Inward, Stage, PDI) & job rework tracking	❌ Verbal QC; reworked operator labor buried in general overhead
Predictive Delay Intelligence	✅ Job Intime, Possible Delay, and Delay reports alert days before deadline	❌ Reactive firefighting; delays discovered on promised delivery date
Scrap & Scrap Income Accounting	✅ Dedicated scrap weight logs & scrap sales revenue credited to job ledger	❌ Scraps quietly disposed off without formal ledger accounting
Accounting Ledger Synchronization	✅ 2-Way automated sync for production vouchers, stock journals & bills	❌ Clumsy manual XML export/import or complete disconnect
Customization Policy	✅ 100% Free customization of Job Cards, routing sheets, and reports	❌ Expensive paid change requests billed by the hour
Deployment Flexibility	✅ Pure Cloud SaaS or 100% Private On-Premise Factory Server	❌ Rigid client-server desktop installs tethered to office LAN

❓ Got Questions?

Frequently Asked Questions

Find answers to common operational questions about Bills of Materials, Job Cards, subcontractor job work, actual costing, and ERPPWA implementation.

Yes. ERPPWA supports nested, multi-level Bills of Materials (BOM) for complex assemblies, sub-assemblies, semi-finished components, and raw materials. It accounts for component scrap percentages, operational process sequences, and pre-production unit cost estimations.

ERPPWA generates digital and printable Job Cards per employee, department, and process. Supervisors can monitor the live Job Tracking by Department dashboard to see which work orders are at cutting, machining, heat treatment, or final assembly with real-time percentage completion.

Yes. When a Job is scheduled, ERPPWA generates a 'Required to Purchase Stock List' comparing BOM requirements against current free store stock. It calculates the exact shortfall and creates Job-Wise Purchase Orders with pre-scheduled delivery dates in 1 click.

ERPPWA calculates actual cost using a true mathematical formula: Used Materials Cost + Direct Machine & Process Expenses + Operator Labor Hours = Actual Production Cost. It provides live variance analysis comparing standard BOM estimates to actual cost.

Yes. ERPPWA records the specific raw material heat codes, batch numbers, and component serial numbers used in each master finished product, ensuring full cradle-to-grave traceability for warranty audits.

ERPPWA manages outside processes with dedicated contractor Delivery Notes. It tracks sent materials, returned finished components, allowable process shrinkage, and contractor service billing with automatic reconciliation.

Yes. ERPPWA provides standardized QC Templates for inward raw materials, in-process stage inspection, and pre-dispatch final inspection (PDI). Rejected items can be routed into dedicated Rework Jobs or scrapped.

ERPPWA includes three predictive delay analytics reports: Job Intime Report, Job Possible Delay Report, and Job Delay Report. Supervisors receive automated alerts before milestone delivery dates breach, allowing proactive machine load rebalancing.

Yes. ERPPWA records generated scrap by job and logs scrap sales revenue directly against job ledger accounts, giving owners an accurate picture of net manufacturing yields and scrap recovery.

Yes. ERPPWA generates printable Job BOM documents detailing raw materials, component drawing references, cutting sizes, and process steps for shop floor operators.

Upon final QC clearance, ERPPWA performs a 1-click Finished Goods Inward entry, closing the Job, updating warehouse stock, assigning serial/batch barcodes, and posting final manufacturing journal entries.

Yes. Manufacturing vouchers, raw material consumption journals, finished goods inward vouchers, and contractor job work bills synchronize seamlessly with standard external accounting platforms and financial ledgers.

Streamline Shop-Floor Manufacturing & Job Costing

Production & Job Costing Audio Overview

The Complete Shop-Floor Production Lifecycle

Sales Order to Job & BOM

Shortage Calculation & Auto-PO

Material Issue & Serial Tagging

Department Routing & Job Cards

Subcontractor Job Work & QC

Finished Goods Inward & Costing

End-to-End Manufacturing & Shop-Floor Features

Multi-Level Bill of Materials (BOM) & Process Templates

Production Jobs, Job Cards & Department Tracking

Smart Job-Wise Material Planning & Shortage Auto-PO

Material Issued to Production & Serial Traceability

Subcontractor & Contractor Job Work Management

Actual Production Costing: Materials + Labor + Overhead

Quality Control (QC), Rework & Scrap Accounting

Machine Management & Predictive Delay Intelligence

100% Free Customization

Private Cloud or 100% On-Premise

Why ERPPWA Outperforms Traditional Legacy Other ERPs

Frequently Asked Questions

Schedule Your Guided Production Module Demo