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Also serving Kochi and Cochin
Rubber goods at Irapuram, plastics around Aluva, rice at Kalady and fabrication for the port and shipyard: Ernakulam makes things, and most of its factories still plan production on a whiteboard.
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Rubber products manufacturing
Compound recipes as multi-level BOMs, batch-wise mixing and moulding with cure times recorded, raw rubber bought at daily market rates, scrap captured per batch, and quality checks at compounding and final inspection for units at Irapuram.
Plastic products units
Moulding jobs by machine and shift, resin and masterbatch consumption against standard, regrind tracked as a by-product, mould maintenance schedules, and make-to-order runs for packaging customers around Aluva and Perumbavoor.
Rice milling
Paddy received by variety and moisture, milling yield and by-products such as bran and husk recorded per batch, seasonal purchase planning, bagged output by grade and brand, and dispatch to wholesalers from the Kalady mills with e-way bills.
Kochi is known for trade and IT, but Ernakulam also makes things. The rubber park at Irapuram holds units compounding and moulding rubber. Plastic product makers cluster between Aluva and Perumbavoor. Rice mills at Kalady run through the season, and fabrication shops serve the port, the refinery and the shipyard. Most are mid-sized and owner-managed, planned by a production manager with a notebook.
Manufacturing ERP software on ERPNext covers bills of materials, production planning, material requirement planning, work orders, job cards, subcontracting, quality inspection and batch costing, tied to purchase, stock and accounts. It answers the questions a factory owner asks daily: can we accept this order, what material is short, where is the job now, and did the last batch make money.
Case studies
BrahMos Aerospace Thiruvananthapuram Ltd (BATL)
BrahMos (BATL) — Secure, Auditable ERPNext Finance & Procurement
BSS Green Life Solar Division
BSS Green Life Solar — ERPNext, CRM & a Geo-Tagged Site-Survey App
Connect N Cabs Tours & Travels Pvt. Ltd.
Connect N Cabs — A Custom Travel ERP That Lifted Fleet Utilisation 35%
Production stops because a bought-out part or a packing material did not arrive, and nobody saw it coming. Material planning explodes the BOM against confirmed orders and current stock, and lists what must be bought and by when.
Many Ernakulam units know their overall profit but not which product earned it. Work orders collect actual material, labour time and overhead per batch, so estimated and actual cost can be compared while prices can still be corrected.
Material sent out for machining, plating or packing often returns light, with no record of scrap. Subcontracting in ERPNext tracks what was supplied, what came back and what remains with the vendor, along with the job-work challan GST requires.
An example
A rubber products unit at Irapuram begins the week with the production planner open. Confirmed orders for the month have been exploded into compound batches and moulding runs, and the material shortfall shows two items: an accelerator that is low and a packing carton the supplier is late on. Purchase orders go out before nine. On the floor, the supervisor pulls the first job card on a tablet, logs the batch weight and cure start, and the stock ledger moves as he does. At four the owner compares last week's actual cost per batch with the estimate, sees one product drifting, and revises its price before the next quotation goes out.
We begin with a plant walk. For an Ernakulam factory that is a short drive from Kadavanthra, so we come more than once: to see a normal day, a changeover and a month-end. BOMs and routings are built with your production staff and tested on a real order. At go-live our people are on the shop floor with the supervisors, not in a meeting room.
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. It is widely used by units of that size because it carries no per-user licence fee and can start simple: BOMs, work orders and stock. Planning, job cards, quality and costing can be switched on as the team gets comfortable rather than all at once.
Yes. Production plans can be driven by sales orders, by reorder levels, or by a mix. Many units make standard items for stock and specials to order, and both run in the same system with the same materials.
Only as much as makes sense. Supervisors can update job cards on a tablet or a shared terminal, on a simple screen showing only their operations. Where even that is impractical, a clerk enters the day's production from job sheets.
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.
KINFRA Rubber Park, Irapurampark
105-acre joint-venture park of KINFRA and the Rubber Board for rubber-based manufacturing; about 36 units.
A 105-acre park run with the Rubber Board for rubber-based manufacturing, where compound recipes, cure cycles and daily raw rubber prices make batch costing the core need.
Source: kinfra.orgPlastic industries cluster, Aluva–Perumbavoorcluster
DC-MSME cluster with a common facility centre (2005-06) for plastic product units around Aluva and Perumbavoor.
A DC-MSME cluster of plastic product units running moulding machines by shift, where resin consumption against standard decides whether a job made money.
Source: dcmsme.gov.inFabrication and general engineering cluster, Kochicluster
Listed by MSME-DI Thrissur as one of the district's major clusters, serving the port, refinery, shipyard and chemical plants with fabrication work.
Fabrication shops serving the port, refinery and shipyard, doing project-style work where plate consumption, subcontracted machining and client hold points must be tracked per job.
Source: dcmsme.gov.inRice mill cluster, Kaladycluster
DC-MSME cluster with a common facility centre run through a millers' consortium; the MSME-DI profile lists it among the district's four major manufacturing clusters.
A millers' consortium cluster where paddy variety, moisture and milling yield per batch are the figures that decide the season's margin.
Source: dcmsme.gov.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