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Also serving Trichur
From goldsmiths' benches to plywood presses and ayurveda boiling rooms, Thrissur makes things in small batches with costly inputs, where a little unrecorded loss is a lot of money.
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Photo: Jpullokaran · CC BY-SA 3.0, cropped · via Wikimedia Commons
Trusted by 200+ organisations across India & overseas — including
Gold and jewellery manufacturing and retail
Job-work issue and receipt in grams with purity, wastage recorded per order, stone and finding consumption, hallmarking sent out and received back as a tracked step, and finished pieces entering showroom stock with their cost attached.
Timber, plywood and furniture
Bills of materials for standard furniture lines, cutting lists and yield tracking from sheet to component, work orders per customer job, and offcuts returned to stock instead of vanishing.
Ayurveda and wellness
Formula-based bills of materials, batch manufacturing records with quality checks at each stage, expiry assigned at production, and traceability from a bottle on the shelf back to the herb lots used.
Manufacturing in Thrissur does not look like a textbook factory. Gold ornaments are made by goldsmiths working on job work, paid by the gram and allowed an agreed wastage. Ayurveda medicines are prepared at Koratty in batches from dozens of herbs according to classical formulae. Furniture and plywood units turn logs into sheets and sheets into wardrobes. Die and mould shops around Avannur cut tooling for other factories. In all of them, material is dear and yield decides the profit.
ERPNext manufacturing gives these units bills of materials, work orders, job cards, subcontracting, batch tracking and production costing in the same system as purchase, stock and accounts. It tells you what was issued, what came back, what was lost on the way, and what each batch truly cost.
Case studies
BrahMos Aerospace Thiruvananthapuram Ltd (BATL)
BrahMos (BATL) — Secure, Auditable ERPNext Finance & Procurement
Dumas Bakes N Meals Private Limited
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Adventure Sports Cover 360 (ASC360)
ASC360 — ERPNext + Mobile App Cut Policy Issuance Time 70%
Gold issued to outside workers is recorded in a notebook and settled from memory. The subcontracting flow in ERPNext records metal issued by weight and purity, ornaments received, and the wastage allowed, so each goldsmith's balance is known at any moment and disputes are rare.
An ayurveda unit often prices from last year's cost sheet. When every herb issue, fuel charge and labour hour is booked to the work order, the cost of each batch is available as soon as it is closed, and pricing can follow reality.
Furniture workshops accept wedding-season orders until the floor is overwhelmed. Work orders with planned start dates, material availability checks and a simple view of workstation load let the owner see the queue before giving a delivery date.
An example
On a Wednesday at an ayurveda manufacturer in the Koratty cluster, the production head releases a work order for a medicated oil from its classical formula, held in the system as a bill of materials that only she and the owner can open. The store issues herbs and sesame oil against it, batch by batch, with the oldest lots first and the quality check at receipt already on record. The boiling runs through the day; fuel and labour are booked to the job card as it goes. At filling, the finished batch receives its number and expiry, and the bottles enter finished stock with the batch's true cost attached, not last year's estimate. A sample goes to the cluster's common lab, and the result is filed against the batch. Next month, when a stockist in another state queries a bottle, the batch record shows every herb lot that went into it.
We begin on the shop floor, not in the conference room. Our consultants follow one product through your Thrissur unit from raw material to dispatch and document each hand-off. Bills of materials and routings are then built with your production head. Go-live is phased, usually stock and purchase first and production second, with someone from Acube on site when the first work orders run.
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. Each outside worker is treated as a subcontractor with his own stock location. Metal sent to him, pieces returned and wastage are recorded against that location, and a statement in grams can be printed whenever you settle. He does not need to use the software himself.
Only the roles you permit. ERPNext permissions can restrict bills of materials to named users, while store and production staff see only the quantities to issue for a given work order. Access is logged, and the data sits on a server under your control.
It can be, provided the scope is kept modest. A small unit may need only bills of materials, work orders and stock, without detailed routing. There is no per-user licence fee, so the system can start small and grow with the business.
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.
Gold Ornaments Industry Cluster, Thrissurcluster
DC-MSME cluster taken up in 2004-05 through MSME-DI Thrissur; the district's jewellery workshops are the backbone of Kerala's plain-gold manufacturing trade
The cluster's workshops depend on metal issued to goldsmiths and returned as finished ornaments, which the subcontracting flow tracks by weight, purity and allowed wastage.
Source: dcmsme.gov.inDies and Moulds Cluster, Thrissur Corporation area and Avannurcluster
DC-MSME cluster (2008-09) for small die, mould and tooling workshops in and around the city; a separate light-engineering cluster is listed at Perinjanam
Tool-room shops make one-off dies and moulds to order, where job cards, machine time and material per job decide whether a quotation was right.
Source: dcmsme.gov.inAyurveda manufacturing cluster, Korattycluster
Consortium-run cluster of several dozen Ayurveda manufacturers with shared testing and validation labs at the KINFRA park, set up with KINFRA and KSIDC
Formula-based batches with shared testing labs need bills of materials, batch records, expiry at production and traceability to the herb lot.
Source: en.wikipedia.orgFurniture Cluster, Thrissurcluster
Common facility centre approved under the MSE-CDP scheme for the district's furniture makers, handled by the MSME-DFO at Thrissur
Furniture makers using the common facility run customer-specific work orders from sheet and timber, where cutting lists and yield tracking keep material from vanishing as offcuts.
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