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Manufacturing

Manufacturing plans and runs production for small and mid-size plants. You define what you make (bills of materials and routings), plan what to make and buy (MRP, master schedule and capacity), and run manufacturing orders on the shop floor from a tablet or phone. Job work under GST is handled with challans and ITC-04, and with Books on, every material movement and order close posts to the ledger.

Who uses it​

  • Manufacturing admin: owns settings, reasons, work centres and the costing method; closes orders; approves engineering changes, large scrap and quality deviations.
  • Production planner: maintains items, BOMs and routings, runs MRP and the master schedule, and creates, confirms and releases orders.
  • Shop floor operator: works the queue at their work centres, records time, quantity and scrap, and fills in checks.
  • Quality inspector: records inspections and places or releases quality holds.
  • Finance admin: reads costing and variance reports.

Before you start​

  • Your company is set up in Thoshika and Manufacturing is switched on for it.
  • Books is on if you want items shared with Books, sales orders as demand and journals for WIP and variances. Without Books, Manufacturing keeps its own store ledger with no journals.
  • Inventory is on if you want bins, lots and FIFO or standard valuation; otherwise stock lives in Books warehouses.
  • People is on if you want labour costed at each worker's rate and work-centre hours taken from shift timings.
  • Staff hold the right Manufacturing roles; operators and inspectors can be limited to their work centres.

Set up​

  1. Settings. Choose number prefixes, the costing method (standard or actual), the default issue method (manual or backflush), the planning horizon and the scrap approval limit.
  2. Reasons. Add scrap, downtime, hold and rework reasons. Downtime reasons carry an OEE loss category.
  3. Work centres. Add each machine, labour or subcontract centre with units, shifts, hours, efficiency, OEE target and machine, labour and overhead rates. Link a People shift and a cost centre where you can.
  4. Items. Set the type (finished, semi-finished, raw material and so on), make or buy, lead time, safety stock, order minimum and multiple, tracking and shelf life.
  5. BOMs. Build each BOM with components, quantities, scrap percentage, consuming operation and issue method. Add alternates and co-products or by-products. Activate a version.
  6. Routings. Add operations in sequence with work centre, setup and run minutes, headcount and inspection checkpoints. Mark subcontracted operations with the job worker and price.
  7. Job workers. Add job workers and principals with GSTIN, state and linked Books party.
  8. Standard costs. Run a cost roll-up and set the results as standard.

Key workflows​

Make to order from a sales order​

  1. Pick an open Books sales order line for a finished good and create a manufacturing order. It is due on the order's delivery date.
  2. Confirm the order to reserve materials and see any shortages.
  3. Release it. Work orders are created per operation and the job card is ready to print.
  4. Issue materials from stores, or let backflush lines be consumed as operations report quantity.

Run an operation on the shop floor​

  1. Open the shop-floor view and pick your work centre, or scan the job card.
  2. Start setup or run with the operators on the job.
  3. Pause with a downtime reason when needed, then resume.
  4. Report good quantity and scrap with a reason, record required checks, and finish. A failed mandatory check puts the order on hold.

Plan with MRP​

  1. Run MRP. It reads open sales orders, forecasts, the master schedule, open orders, stock and safety stock.
  2. Review suggestions, each pegged to the demand it covers, and the exceptions to expedite or reschedule.
  3. Convert make suggestions into manufacturing orders and buy suggestions into Procurement requisitions or Books purchase order drafts.
  4. Check the load chart per work centre and run finite scheduling to set dates.

Send material for job work​

  1. Create a job work challan to the job worker with items, values and the e-way bill number where required. Stock moves to "with job worker".
  2. Receive processed goods back, with any waste, into WIP or stores. A job charges bill is created in Books.
  3. Watch reminders before the one-year (inputs) or three-year (capital goods) limit. Goods not returned in time are flagged as deemed supplied.
  4. Export ITC-04 for the period as CSV for the GST offline tool.

Close an order​

  1. When all quantity is received (or the order is closed short), close it.
  2. Remaining WIP is cleared to material, labour and overhead, scrap and subcontract variances, or under actual costing, adjusted into finished stock.

India specifics​

  • Job work follows GST section 143 with Rule 45 and Rule 55 challans, return limits, deemed supply and job charges under SAC 9988.
  • ITC-04 covers sent, received, sent between job workers and supplied from the job worker's premises, exported as CSV. Filing on the GST portal is manual.
  • Inventories split into raw materials, work in progress and finished goods as Schedule III expects.
  • Variance and consumption reports give a material, labour and overhead build-up useful for cost records; they are not the CRA forms.

Works with other apps​

  • Inventory: stock, lots and plant warehouses through the shared stock engine.
  • Books: sales orders, purchase orders, journals, job charges bills and job work invoices.
  • Procurement: requisitions from MRP buy suggestions.
  • CRM: won deals arrive as Books sales orders, and the order shows its origin.
  • People: workers, cost rates and shift timings.
  • Maintenance and Quality: breakdown downtime for OEE, incoming inspection, NCRs and CAPA.
  • The mobile app lets operators scan job cards and report work, and planners review orders and MRP suggestions.

Next steps​