Loading…
Loading…
Also serving Quilon
Cashew kernels, ceramic ware, coir mats and processed minerals: Kollam makes things in batches where yield decides profit, and that is exactly what a manufacturing ERP measures.
Official ERPNext Partner · 100+ ERP projects · Since 2011
Or call +91 62358 66111
Photo: Arunvrparavur · CC BY-SA 4.0, cropped · via Wikimedia Commons
Trusted by 200+ organisations across India & overseas — including
Cashew processing and export
Process-stage work orders from roasting through shelling, drying, peeling and grading, with several outputs including shell and husk, job work to outside units, and yield and cost by lot, origin and supplier.
Mineral sands and ceramics
Recipes for clay bodies and glazes, kiln-batch tracking with rejection recorded at each stage, fuel and power allocated to the batch, and preventive maintenance for kilns and separation plant.
Wood and furniture
Cutting lists and bills of materials by design and size, timber issued and offcuts returned, work passed between a common facility centre and small units, and finished stock held by model and finish.
Manufacturing in Kollam is mostly process work, and process work hides its losses. A cashew factory does not assemble parts. It takes a natural raw material of uncertain quality and breaks it into many saleable grades plus by-products. A ceramics unit at Kundara fires batches where a share will crack. Whether the month made money depends on yields few owners see until the accountant has finished.
Manufacturing ERP software on ERPNext brings bills of materials, production planning, work orders, job cards, subcontracting, quality inspection, batch tracking and production costing into one system linked to stock and accounts. It handles one-input, many-output processes as well as conventional assembly, so actual yield and cost per batch are known while there is still time to act on them.
Case studies
BrahMos Aerospace Thiruvananthapuram Ltd (BATL)
BrahMos (BATL) — Secure, Auditable ERPNext Finance & Procurement
Dumas Bakes N Meals Private Limited
Dumas Bakes N Meals — ERPNext Lifted On-Time Deliveries by Over 40%
Connect N Cabs Tours & Travels Pvt. Ltd.
Connect N Cabs — A Custom Travel ERP That Lifted Fleet Utilisation 35%
Prices are often quoted on a standard yield assumed years ago. Production entries that record actual inputs, outputs, labour and fuel for each batch produce a real cost per kilo of every grade, so the sales desk knows which orders make money.
Cutting test results, moisture readings and inspection reports usually stay in a laboratory file. Inspections linked to purchase receipts and work orders attach those results to the batch, and a supplier's record builds up across seasons.
The production manager decides each morning what to run from what he can see. Planning against confirmed orders and available stock shows in advance which grades are short, what must be processed and what raw material to release.
An example
A kiln on the Kundara belt is opened on Tuesday morning after its overnight cool. The supervisor records the good pieces and the cracked ones at the bench, against the batch number created when the body and glaze were issued on Sunday. That is the whole of his data entry. By the time the owner reaches the office the batch shows its input weight, its output by size, its rejection at each stage, and the fuel and power charged to it. An earlier batch from the same body mix sits beside it for comparison, and the difference is a question worth asking today.
We spend the first days on your factory floor in Kollam, following material from the gate to the packing room and noting where quantities are, or could be, measured. The system is configured to those measuring points. Supervisors are trained at their own sections. We advise going live with stock and production entries first, and switching on planning and detailed costing once the data is dependable.
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. Instead of a rigid recipe, production is recorded as actual input and actual outputs for each lot, and the system values the grades and by-products produced. Standard yields can still be held for comparison, which is how variance by lot and supplier appears.
Through subcontracting. Material sent out is recorded against the job worker, stays on your books as stock at their location, and is reconciled when kernels come back. Job charges post to the batch cost, and pending quantities with each unit stay visible.
No. We aim for a few entries at natural points: material issued, output weighed, batch closed. These can be made on a tablet at the scale. If entry is a burden it will be skipped, so keeping it light is part of the design.
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.
Kundara industrial beltpark
Historic industrial town on the Kollam–Sengottai railway with the state-owned Kerala Ceramics (china clay and kaolin) and Kerala Electrical and Allied Engineering Company (KEL), plus Technopark Kollam since 2011.
An old state-sector town making china clay and kaolin products and electrical equipment, where batch firing and rejection at each stage decide whether a month was profitable.
Source: kollam.nic.inChavara mineral-sands belt (KMML, Sankaramangalam)park
Government of Kerala undertaking at Sankaramangalam, Chavara, running an integrated titanium dioxide operation from beach-sand mining and mineral separation to synthetic rutile and pigment plants.
An integrated operation running from beach-sand mining and mineral separation through to synthetic rutile and pigment, a chain of stages where each transfer is a costing point.
Source: kmml.comWood Processing Cluster, Kollam (Wood Empire consortium)cluster
MSE-CDP cluster with a common facility centre under MSME-DFO Thrissur; the district profile records 66 functional units, about 500 jobs and a diagnostic-study turnover of Rs 250 crore, with no exports.
Functional units sharing a common facility centre pass material between themselves constantly, which is subcontracting that has to be reconciled rather than trusted.
Source: dcmsme.gov.inPlaces and organisations are named for local context only. Acube Innovations is not affiliated with or endorsed by them.
Get a clear plan, an honest timeline, and a fixed scope. Talk to a real expert today — whether or not you work with us.
or write to info@acube.co
Kochi (Kadavanthra & Infopark) · Thiruvananthapuram · across India & overseas · In business since 2011