Tracking the Stages in your Production is now at your fingertips

In today’s fast-paced, digital-first marketplace, manufacturers are under constant pressure to deliver faster, better, and more cost-effectively. Whether it’s an apparel manufacturer producing hundreds of SKUs or an FMCG brand running batch-wise production, knowing the exact status of your production process in real-time is no longer a luxury—it’s a necessity. The ability to monitor and control each production stage ensures operational efficiency and responsiveness to market demands. In this context, tracking the stages in your production process becomes the equivalent of a BP machine for someone with a heart condition. You may not always feel the stress points, but unless monitored closely, small issues can lead to serious problems.

Why Real-Time Production Tracking Is a Game Changer

Historically, production tracking involved paper-based or siloed systems. Operators manually entered data, which was often cross-verified by supervisors and then made its way to decision-makers after long delays. Such lagging information rarely supports timely decision-making.

In contrast, real-time production data empowers businesses to act immediately. Whether it’s identifying a process bottleneck, adjusting manpower, or reallocating resources, the availability of accurate data in real time enhances responsiveness.

With Ginesys ERP, manufacturers get access to live shop floor data. This is not merely a data capture exercise—it provides meaningful, actionable insights that enable better planning, faster response, and informed decisions. It leads to reduced downtime, improved productivity, and cost savings.

Bringing Production Visibility to Life with Ginesys ERP

Ginesys ERP offers a comprehensive production tracking system that digitizes every step of the manufacturing process. From job order creation to final product dispatch, every detail is recorded and monitored. Let’s understand this with an example:

In manufacturing a designer shirt, different parts such as front, back, collar, and sleeves go through individual processes like dyeing, embroidery, and cutting before being assembled. Ginesys allows seamless tracking of these parallel activities.

• Digital Job Orders: Automatically created and assigned within the system.
• Stage Monitoring: Each step in production is tracked with timestamps and operator logs.
• Inventory Linkage: Materials consumed and output generated are recorded in real time.
• Real-Time Collaboration: Multiple teams across departments can access the same live data.

This digital model creates a real-time, virtual replica of the factory floor, ensuring better control, transparency, and accuracy.

Track, manage, and optimize your production seamlessly with Ginesys.

In-depth WIP Monitoring

Work-in-progress (WIP) is often the most volatile phase of production. Delays, reworks, and wastage generally accumulate during this stage. Ginesys addresses this with meticulous WIP monitoring.

• Progress Tracking: At any given time, users can see how much of the job is completed and what remains.
• Time Measurement: Tracks how long each batch remains at a specific stage.
• Operator Accountability: Identifies who is responsible for each job and what output is expected.
• Quality Monitoring: Highlights stages where errors or reworks occur frequently.

This monitoring not only boosts efficiency but also ensures greater accountability and process discipline.

Seamless Integration of Production & Inventory

The Ginesys production module is tightly integrated with inventory management. As production progresses, inventory levels update automatically.

• Material Issuance: Raw materials issued for a job are instantly deducted from inventory.
• Consumption Tracking: Actual consumption is tracked and compared with the BOM.
• Auto Stock Update: Finished goods are added to stock upon completion.
• Shortage Alerts: The system flags material shortages in advance to avoid disruptions.

This leads to better material planning, lean inventory, and reduced working capital needs.

Powerful Dashboards for Managers

Ginesys ERP provides dynamic dashboards tailored for production managers. These dashboards are designed to help users make data-driven decisions with minimal delay.

• Live Job Order Status: Real-time view of all ongoing job orders and their current stages.
• Performance Metrics: Displays KPIs like average completion time, rejection rate, and machine downtime.
• Resource Utilization: Monitors how machines and operators are being used.
• Backlog Identification: Instantly shows jobs or batches that are lagging.

This enables better allocation of resources and timely course correction.

Book a personalized demo and explore how Ginesys simplifies production management.

Identifying & Eliminating Bottlenecks

Every production line has choke points, but Ginesys enables real-time identification and resolution.

• Time Deviation Alerts: If a task takes longer than expected, the system flags it.
• Consumption Analysis: If material usage deviates from standards, it gets reported.
• Checkpoint Monitoring: WIP stages are monitored to detect and resolve delays.
• Continuous Feedback: Enables ongoing process refinement through insights.

As a result, businesses can reduce lead times and improve process efficiency continuously.

Managing External Job Work & Outsourced Production

Outsourced production adds complexity. Ginesys simplifies it through integrated job work features.

• Job Assignment: Easily assign tasks to external vendors directly from the ERP.
• Live Vendor Updates: Vendors can submit progress in real time.
• Material Reconciliation: Automatically match materials issued vs. items received.
• Document Management: Maintains digital records of GST-compliant challans and invoices.

This reduces errors, miscommunication, and delays, ensuring a smoother job work process.

Maintaining an Audit-Ready Digital Trail

Ginesys keeps a comprehensive digital record of every action in the production process.

• User Logs: Tracks who performed which task and when.
• Stage-wise History: Records time taken at each production stage.
• Exception Handling: Logs deviations and corrective actions.
• Batch Traceability: Provides full traceability at batch and SKU levels.

This audit trail is invaluable for compliance, quality checks, and performance reviews.

Proactive Alerts & Exception Notifications

Real-time alerts are integral to modern production. Ginesys supports customizable notifications.

• Delay Warnings: Alerts if job order crosses the defined timeline.
• Material Variance Alerts: Flags when material use deviates from BOM.
• Idle Stage Notifications: Identifies WIP stagnation.
• Vendor Delay Alerts: Highlights delays in outsourced job work.

These alerts help in early intervention and reduce the chances of missed deadlines.

Seamless Integration Across the Ginesys One Ecosystem

Production doesn’t work in isolation. With Ginesys One suite, everything connects seamlessly.

• Procurement Alignment: Purchase planning aligns with production requirements.
• Inventory Sync: Shared inventory data avoids duplication.
• Sales Collaboration: Sales forecasts drive production planning.
• GST Compliance: Auto-generated job work documents ensure legal compliance.

This cross-module integration ensures smoother operations and one version of truth.

Analytics & Forecasting for Future Planning

Digitized data enables future-oriented decisions. Ginesys helps you plan smarter.

• Time Estimation: Predicts time required for similar job orders.
• Performance Analysis: Ranks best-performing operators and machines.
• Optimized BOM: Refines bill of materials based on historical data.
• Delivery Scheduling: Improves accuracy in order commitment.

With every cycle, your processes get more refined and profitable.

Remote Production Management

With cloud-based tools and mobile accessibility, Ginesys allows production heads to manage remotely.

• Live Monitoring: View production dashboards from anywhere.
• Mobile Alerts: Get notified of issues in real time.
• Remote Approval: Authorize job orders and changes from mobile devices.
• Factory Independence: Manage multiple units without being physically present.

This leads to greater agility and faster decision-making.

Get in touch and discover how Ginesys can transform your production operations.

Adaptive Workflows for Any Manufacturing Model

Ginesys adapts to diverse manufacturing models, whether batch production, make-to-order, or continuous manufacturing.

• Multi-stage Process Mapping: Handles complex production flows.
• Subcontracting Integration: Manages both internal and external job work.
• Assembly Tracking: Monitors component assembly in real time.
• Quality Checks: Integrates QA/QC at various checkpoints.

The flexibility of workflows ensures that Ginesys fits your process, not the other way around.

Real-time production tracking is now a necessity in competitive manufacturing. Ginesys ERP delivers complete visibility, accurate tracking, seamless integration, and proactive alerts across every production stage.

With its tightly integrated workflows, digital audit trails, job work tracking, and real-time dashboards, Ginesys becomes your command center for efficient, cost-effective, and transparent manufacturing.

Transform your operations with Ginesys ERP’s Production Management—where every stage is at your fingertips. Request a Demo today and see it in action.