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Production Management

Ginesys ERP is the best manufacturing software for process manufacturing like manufacturing garments, shoes, bags, foods items and more. It is very simple to manage and yet can handle complex requirements of multiple factories, jobbers and warehouses with different items going through different stages of production at various factories. If you are looking for an ERP that is covering all aspects of manufacturing and has a solid distribution and retail management function then Ginesys ERP is the right choice.

Normal Production Flow

Sampling or Sample Making

First some raw material is issued ad-hoc and almost complete samples are created to understand how the final product would look, feel and move as a complete unit. This would also give a fair idea of the consumption of raw materials required for the actual production.

Planning and Purchase of Raw Materials

Here you need to make a cost-sheet to set the maximum retail price or recommended retail price of an item by adding a desired markup to the input costs of materials and labour. Once a sample run has been completed, the production manager gets a production plan of the desired quantity of the item with various size ratios. This quantity could be derived from a sales projection (referred to as made-to-stock production) or from a sales order (referred to as made-to-order production).

Processing

Once the raw materials are received for the first stage of production the raw materials are issued to the first processing unit or job-work factory and from thereon it is a work-in-progress item that is repeatedly issued and received with value additions. For example, in a garment manufacturing process, the stages are dyeing, fabric cutting, stitching, ironing, finishing and packing. Processes and their sequencing depend on the part of the garment being manufactured. The entire process could be done on an outsourced basis with the raw materials being supplied to the contract manufacturer or it could be a managed outsourcing in part with few of the steps happening in-house and few steps being taken up by contractors.

Packing and Shipping

The final stage is putting the finished goods in a bag or box with the labels and ensuring it is ready for dispatch.

Top Features of Production Management

Plan Production with Confidence

Ginesys ERP allows you to manage production across thousands of SKUs with confidence. You can plan for both make-to-order deliveries and make-to-stock production. You can start with a sample run, move to production costing estimates, derive an MRP, create a process route and plan the raw material purchase for the production lot quantity you are going to make. 

Process Management with Process Routes and Groups

The Ginesys production module provides a sophisticated multi-level Bill of Materials (BoM) system. This system allows for detailed management of various manufacturing processes, routes, sub-assembly items, and alternate plans, ensuring efficient process management in garment manufacturing, footwear manufacturing, bags manufacturing and other sectors.

Track Different Production Lines of Parts of a Single Item

Assembly items are useful in case the finished product has various parts that need to be manufactured separately and put together to make the finished item. In the case of a shirt, a collar may be manufactured separately from a cuff and the rest of the shirt.

Manage Sub-Contracting with Ease

Jobbers are a category of suppliers who are doing the contract manufacturing for various parts of the production process.The production module in Ginesys ERP includes tools for managing job orders and receipts along with the cost rates for the process manufacturing. This system helps in tracking and controlling the cost of the production that is to be paid for the processes to various job-workers.

Handle Complex Raw Material Requirements

Ginesys ERP includes comprehensive raw material management, allowing businesses to track and manage both direct materials (integrated into the final product) and indirect materials (used during the production process). You can issue raw material inputs for the process manually as per your estimate, or automatically as per the consumption factor given in the bill of materials. In case any production is stuck, you can clear out the stuck Work-In-Progress with a single click.

Simple Item Conversions

Ginesys ERP facilitates quick and simple item conversion transactions, which are sometimes required when you do not want the hassle of creating processes, mapping jobbers and more. You just need to enter the source item and quantity and the output item and output quantity along with the manufacturing cost of the output item.

Easily Track Landed Cost of Finished Goods and WIP Valuation

The software provides detailed insights into the landed cost of finished goods and the valuation of Work-in-Progress (WIP) or intermediate goods. This is extremely useful for the finance team as they can get a ready and precise picture of the current on-hand value locked in finished goods, raw materials and the WIP. They can also see a breakdown of the cost in terms of materials and labour.

Conclusion

Overall, the Ginesys Production module is a great enhancement to India’s most loved Retail ERP. It can handle complex process manufacturing requirements of materials and contract management with ease and give detailed reports on WIP value, production progress and expected delivery and finished goods costing.

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