Industry
Manufacturing
Shop floor counts during the shift. Manufacturers make money on uptime, yield and on time delivery. Most Indian plants already run Tally or an ERP for accounts, but production plans, machine status, quality checks and approvals still live on whiteboards, registers and WhatsApp groups, which is where software pays back fastest.
- Engineering and auto components
- Plastics and packaging
- Textiles and garments
- Food processing
- Electrical and electronics assembly
- Ceramics and building materials
The pressure points
What slows manufacturing teams down
- No live view of production
- Output, downtime and scrap are written in registers and entered next day, so the plant head learns about a stopped line hours later.
- Quality found too late
- Inspection records are on paper, so when a customer complains it takes days to trace the batch, the raw material lot and the operator.
- Approvals and purchasing on paper
- Indents, purchase orders and gate passes need signatures from people who are often away, so material arrives late and the line waits.
- Maintenance by breakdown
- Preventive maintenance schedules exist in a file but are skipped when output is pressing, and spares are not in stock when the machine fails.
Systems this sector runs on
The software we build and connect
Each of these can be built new, extended from what you already use, or connected to your existing ERP and accounting.
- Manufacturing Execution SystemMESWork orders, machine and operator booking, downtime reasons and OEE by shift, linked to the production plan.
- Enterprise Resource PlanningERPBOMs, inventory, costing, GST invoicing and e-way bills, often extending the Tally, Odoo or SAP Business One setup you already run.
- Enterprise Asset Management and CMMSAsset maintenancePreventive schedules, breakdown tickets, spares linked to machines and MTBF and MTTR reporting.
- Procure to Pay and Vendor ManagementProcurementIndent to PO to GRN with approval rules, vendor rating and three way match against invoices.
- Supply Chain and Warehouse ManagementSupply chain and WMSRaw material, WIP and finished goods by location with FIFO, batch and expiry control.
- Business Intelligence and Management DashboardsBI and dashboardsPlant level views of output, OEE, scrap, cost per unit and dispatch performance.
Built for this sector
Systems specific to manufacturing
The work that generic software does not cover, and where most of the value sits.
- Quality management and traceability
- Incoming, in process and final inspection plans, NCRs, CAPA and batch genealogy from raw material lot to customer dispatch.
- Machine data capture
- Reading cycle counts and status from PLCs over OPC UA or Modbus, or simple IoT counters on older machines, into the MES.
- Vendor and job work portal
- Suppliers see POs and schedules, upload ASNs and invoices, and track job work material sent out under GST rules.
- Production planning board
- A capacity aware schedule by machine and shift that the planner can drag and adjust, with material availability checks.
Where AI helps
AI use cases with a clear return
Visual defect detection
Cameras on the line flag surface defects, dimension issues or missing parts, with images stored against the batch.
Defects are caught at the station, before parts reach the customer, and inspectors focus on borderline cases.
Invoice to PO matching
An agent reads supplier invoices, matches them to POs and GRNs, and routes mismatches in price or quantity to purchase.
Accounts teams stop keying invoices and payment delays from mismatches come down.
Predictive maintenance
Uses vibration, temperature and run hour data to flag machines likely to fail before the next planned stop.
Fewer unplanned breakdowns and better timed spares orders.
SOP and manual assistant
Operators and maintenance staff ask questions in Hindi, Gujarati or English and get answers from SOPs and machine manuals.
New staff become productive sooner and fewer calls go to the few senior technicians on each shift.
What your team would see
- OEE (this week)
- 71.4%
- First pass yield
- 96.2%
- Unplanned downtime
- 14.5 hrs
- On time dispatch
- 88%
Daily OEE, %
Downtime by reason, % of hours
- Breakdown34
- Changeover26
- Material wait19
- Quality hold12
- Power cut9
A sample of the kind of dashboard we build for this sector. Figures are illustrative.
Connects with
- Tally, SAP Business One or Odoo
- PLCs via OPC UA or Modbus
- Weighbridges and barcode printers
- GST e-invoice and e-way bill portals
- Vendor email and WhatsApp
- Biometric attendance systems
Rules we design for
- Factories Act 1948
- ISO 9001
- IATF 16949
- ISO 14001
- ISO 45001
- BIS Quality Control Orders
Read more
Work and writing for this sector
- Project · O2EReplacing a legacy ERP with a custom cloud ERP for a mid sized manufacturer40%Gain in operational efficiencyRead the case study
- Project · O2EProcurement and inventory ERP for a manufacturer with three warehouses60%Reduction in stockoutsRead the case study
- Project · FDEBuy side due diligence and post merger integration for a mid market acquisitionA mid sized flexible packaging manufacturer in Gujarat acquiring a regional competitor in MaharashtraRead the case study
Before you start
Manufacturing: common questions
Do we have to replace Tally?
No. Many plants keep Tally for accounts and GST, and we add MES, quality and procurement modules that post vouchers to Tally automatically.
Our machines are old. Can we still collect data?
Yes. Older machines can use low cost counters and sensors, or operators can log events on a tablet at the station. We start with what is practical and add automation later.
How long does an MES rollout take?
A first line or cell is usually live in 5 to 7 weeks, then extended plant wide. Starting small lets operators shape the screens before every line depends on them.
Talk to us
Working in manufacturing?
Tell us which process hurts most. Someone who knows the sector will reply with two or three options and rough hours.
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