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Also serving Mangalore and Mangaluru
From fishmeal plants at Ullal to fabrication shops in Baikampady, Dakshina Kannada's factories are mostly mid-sized, owner-run and short of one thing: a true cost per batch.
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Metal fabrication and engineering
Project-wise work orders, material test certificates attached to heat numbers, subcontracted galvanising and machining tracked out and back, inspection records and dispatch documentation for plant customers.
Cashew and marine processing
Process manufacturing with multi-stage yield, by-products such as shell and fish oil, grade-wise finished goods, piece-rate wage inputs and lot traceability to the export shipment.
Plastics and packaging
Extrusion and moulding units, including those expected in the plastics park being developed at Ganjimutt, run batch costing by resin lot, regrind tracking and mould-wise output.
Manufacturing in Dakshina Kannada rarely makes headlines beside the refinery, but it employs the district. Cashew factories shell, peel and grade. Seafood units freeze and pack for export. Workshops in the Baikampady industrial area fabricate structures, tanks and skids for the petrochemicals belt. Food units and packaging plants fill the smaller estates at Karnad and Puttur. Most plan production on a whiteboard and learn their costs from the auditor.
ERPNext manufacturing covers bills of materials, work orders, job cards, material requirement planning, subcontracting, quality inspection, batch tracking and production costing, tied to purchase, stock and accounts. Acube configures it to your process, whether a process industry with yield loss or a job shop building to drawing. A Mangalore factory owner can then see what each order consumed and what it earned.
Case studies
BrahMos Aerospace Thiruvananthapuram Ltd (BATL)
BrahMos (BATL) — Secure, Auditable ERPNext Finance & Procurement
Cochin Technical College
Cochin Technical College — Custom ERP Cut Admission Processing Time by Over 60%
Connect N Cabs Tours & Travels Pvt. Ltd.
Connect N Cabs — A Custom Travel ERP That Lifted Fleet Utilisation 35%
In cashew and seafood processing, profit lives in the yield. Recording input and graded output per lot shows yield by supplier, by shift and by line, while there is still time to act.
Fabricators send material out for machining, galvanising or painting and lose track of it. Subcontracting in ERPNext records what went, what returned and what the job worker still holds.
Steel and consumable prices move monthly. Costing from current bills of materials and actual job consumption lets an engineering unit quote the next tender with confidence.
An example
A fabrication shop in Baikampady takes a work order for a pipe skid for a plant in the refinery belt. The cutting list comes from the bill of materials; plates are issued from stock with their heat numbers, so the material certificates follow the job. Two flanges go out to a machining shop in Yeyyadi under a subcontract entry and return marked against it. The welding supervisor closes job cards from a tablet at the end of each shift, and the costing screen shows consumables and labour against the estimate while the job is still open. At dispatch the inspection release note, packing list and e-way bill print together. When the next tender arrives, the estimator prices it from this job's actual cost.
We start on the shop floor. A discovery visit to your unit in Dakshina Kannada follows material from gate to dispatch and notes every register on the way. Bills of materials, routings and costing rules are then configured remotely from Kochi in Kerala, and tested with your production data. We return to Mangaluru for supervisor training and stay through the first production cycle.
Discovery. Your products, bills of materials, routings and how production is planned today.
Blueprint and fixed scope. A clear plan, the deliverables and the timeline, agreed in writing before configuration starts.
Configuration. Bills of materials, work orders, job cards, quality checks and costing.
Data migration. Items, bills of materials and opening stock, including work in progress.
Training, go-live and support. Your team tests on real data, we stand beside you at launch, then support continues under a plan.
The scope and timeline are agreed in writing before work starts.
Yes. Process loss, multiple outputs from one input and grade-wise finished goods are supported. Norms are set per item and the variance from norm is reported per batch, which is the figure owners most want.
We design floor entries to be few and simple, often on a tablet or phone with Kannada labels, or captured by one data entry person from job cards. The system must suit the floor, not the reverse.
Piece-rate output can be recorded against workers and carried into payroll, which suits the cashew and beedi wage systems found across Dakshina Kannada. PF and ESI are calculated in the same payroll.
After a first conversation about your products, plants and how production is planned and costed today, we agree the scope and send you a written quotation. The price, the deliverables and the timeline are fixed against that scope before any work starts, so nothing grows without your sign-off.
You speak to someone who does this work, not a call centre. They ask about what you make, how production is planned and where costing breaks down. If it looks like a fit, we agree the scope and put it in writing, with the timeline, before any work starts. If it does not, we tell you.
Metal fabrication and engineering units, Mangalurucluster
About 3,250 metal-based (steel fabrication) and 450 engineering MSEs as of March 2012, many supplying the refinery, fertiliser and port-side plants; engineering goods are a leading export.
Metal-based and engineering MSEs run into the thousands, per the DC-MSME profile, mostly job shops building to drawing for the refinery, fertiliser and port-side plants. Their costing is per work order.
Source: dcmsme.gov.inPuttur Industrial Areapark
Small estate of about 21 acres with 36 plots, 34 units in production as of 2011-12; serves the interior taluk towns.
A small estate serving the interior taluk towns, where a few dozen units make food products, packaging and building materials in batches, on floors without a computer at every station.
Source: dcmsme.gov.inKarnad Industrial Area, Mulkipark
About 66 acres with 86 plots and 69 units in production as of 2011-12, on the northern edge of the district near Mulki.
About sixty-nine units were in production near Mulki as of 2011-12, per the DC-MSME profile: owner-run engineering and food units that plan production on a whiteboard.
Source: dcmsme.gov.inPlastic Park, Ganjimuttpark
A 104-acre plastics park being developed by KIADB under a central scheme costed at about Rs 62.77 crore; listed as ongoing on the state investment portal, so do not describe it as operational.
A plastics park is being developed at Ganjimutt under a central scheme, still ongoing. Moulding and extrusion units that settle there will need resin-lot costing from day one.
Source: investkarnataka.co.inPlaces and organisations are named for local context only. Acube Innovations is not affiliated with or endorsed by them.
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Kochi (Kadavanthra & Infopark) · Thiruvananthapuram · across India & overseas · In business since 2011
