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OperationsManufacturing

BOMs, routings, MRP and a shop-floor view, with GST job work and production costs posted to Books.

Manufacturing plans and runs production for small and mid-size plants. It covers bills of materials with versions and engineering changes, routings and work centres, manufacturing orders, a tablet view for the shop floor, MRP and capacity planning, job work under GST section 143 with ITC-04, and standard or actual costing posted to Books.

Key capabilities

  • Multi-level BOMs with versions and ECO approval
  • Manufacturing orders and a shop-floor tablet view
  • MRP, master schedule and finite capacity planning
  • Job work challans, return limits and ITC-04
  • Standard or actual costing with variances in Books
  • Lot genealogy from raw material to customer

Dashboard

Planners and plant heads see the state of production, planning and job work for the financial year in one place.

  • Open and late orders, OEE for the last seven days and work in progress value tied to the ledger
  • Material shortages, quality holds, scrap this month and engineering changes in approval
  • MRP make and buy counts with exceptions
  • Planned versus produced by week and OEE by work centre
  • Orders running now, quality holds and open job work challans

Items, bills of materials and engineering changes

Keep product structures accurate over time and change them under control.

  • Items with stock, BOMs, where-used, routings, cost roll-up and lots
  • Multi-level BOMs with phantom sub-assemblies, scrap percentage and alternates
  • Co-products and by-products with a cost share
  • BOM versions with effective dates, one active per date
  • Engineering change orders approved before the new revision takes effect
  • Drawings and documents attached to BOMs and routings

Work centres and routings

Describe where and how each product is made.

  • Work centres with units, shifts linked to People schedules, efficiency, OEE target and cost and overhead rates
  • Daily capacity worked out from units, shifts, hours and efficiency
  • Routings with setup and run times per operation
  • Subcontracted operations sent to a default job worker
  • Inspection checkpoints on operations

Manufacturing orders and work orders

Release orders to the floor and follow every operation to the finished goods receipt.

  • Manufacturing orders from sales orders, MRP, reorder rules or by hand
  • Material reservation, manual issue or backflush, and returns to stores
  • Rework and disassembly orders, partial receipts and close short
  • Work orders per operation, with a planner view across all orders
  • Order detail with materials, work orders, outputs, lots, quality, costs and journals
  • Job card PDF with a barcode for scanning

Shop floor

Operators run their queue from a tablet or phone and record what happened as it happens.

  • Work centre queue in sequence and due order; scan or type a job card to open it
  • Start, pause with a downtime reason, resume and finish operations
  • Report good quantity and scrap with reasons
  • Labour time by worker, costed from People when available
  • Mandatory checkpoints, with a hold on failure
  • Improvement suggestions from operators on each operation

MRP, master schedule, capacity and forecasts

Work out what to make and buy, and when, from real demand and supply.

  • MRP with lead times, safety stock, lot sizing and pegging to the demand it covers
  • Regenerative and net-change MRP runs, across several plants
  • Exceptions to expedite, reschedule in or reschedule out
  • Suggestions converted to orders, Procurement requisitions or Books purchase order drafts
  • Monthly forecasts consumed by actual orders, and a 12-week master production schedule with available-to-promise
  • Load per work centre and finite scheduling with a Gantt chart

Quality

Check product during production and stop what fails.

  • In-process inspections with measurements against limits
  • Holds placed by a failed checkpoint or by hand
  • Release by use as is, rework or scrap, with deviation approval
  • Full quality management with Maintenance and Quality when it is on

Lots and traceability

Trace every lot from supplier to customer.

  • Output lots and serials with expiry
  • Consumed lots recorded on every issue
  • Genealogy back to supplier bills and forward to customer invoices

Job work

Send material to job workers and track it until it comes back.

  • Challans out and in for materials, semi-finished goods and capital goods
  • Material at job workers held in its own inventory account
  • Return limits tracked with reminders and deemed-supply flags
  • Job charges bills and invoices raised in Books

Costing and accounts

Know what each order really cost and post it to the ledger as it happens.

  • Standard cost roll-up of material, labour, machine, overhead and subcontracting
  • Standard or actual costing method
  • Issues, labour absorption, receipts and job work posted to WIP and inventory in Books
  • Material price and usage, labour and overhead, scrap and subcontract variances on close
  • WIP valuation, cost variance and material consumption reports

Reports and settings

See how the plant is performing and set the rules it runs by.

  • Plan versus actual, OEE, scrap, material consumption and labour reports
  • Downtime, scrap and deviation reasons
  • Job worker list and planning defaults
  • Approvals for engineering changes, scrap and deviations
Screens

Manufacturing in the product

India

Indian rules, built in

Job work and inventory reporting follow GST and Indian accounting rules.

How Thoshika handles Indian compliance

  • Job work out and in under GST section 143, with Rule 45 and Rule 55 challans
  • Return limits of one year for inputs and three years for capital goods, with deemed-supply flags and reminders
  • ITC-04 tables exported as CSV for the GST offline tool
  • Job charges bills and invoices in Books under SAC 9988
  • Schedule III split of raw materials, work in progress and finished goods; MO numbers by financial year
Mobile

Manufacturing on Android and iOS

Manufacturing is in the Thoshika app, under the app switcher, for operators on the floor and planners away from their desk.

About the mobile apps

On the phone

  • My work centre queue, with camera scanning of job card barcodes
  • Start, pause with a reason, resume and finish operations
  • Report good quantity and scrap with reasons, and record checkpoints
  • Dashboard of orders in progress, late orders, shortages, holds and OEE
  • Order list and detail to release and confirm orders
  • MRP suggestions to convert or dismiss, and approvals
Who uses it

Roles in Manufacturing

Every person signs in once. Roles decide what they see, and can be limited to a location, branch or other scope where the app supports it.

Manufacturing admin

Owns settings, work centres and costing method; closes orders and approves ECOs, scrap and deviations.

Production planner

Maintains items, BOMs and routings, runs MRP and the schedule, and creates and releases orders.

Shop floor operator

Works orders at their work centres: start, pause, report quantity and scrap, record checks.

Quality inspector

Records inspections and places or releases quality holds.

See Manufacturing with your own processes

Manufacturing is available on its own or as part of Thoshika One, with every app for every employee.