Keep Your BOM, Production, and Floor Inventory Perfectly in Sync
Multi-level BOM, production planning, OEE tracking, and quality control for discrete and process manufacturers.
Problems We're Built to Solve
These aren't edge cases — they happen every day in operations like yours.
BOM Accuracy Failures
Multi-level BOM maintained in Excel. Engineering changes are not propagated. Production issues wrong components; rework eats into margins.
Production Downtime
Unplanned equipment breakdowns with no preventive maintenance schedule. Average unplanned downtime is 14% of available production time.
Quality Rejections
In-process QC done on paper; results never linked to production batch. Root cause analysis is guesswork because data is not captured at source.
Raw Material Stock-outs
MRP not tied to live sales orders. Purchasing reorders based on gut feel. High-velocity raw materials stock out mid-batch, halting the production line.
Costing Inaccuracy
Standard cost set annually in a spreadsheet. Actual consumption variance is never captured. Finance cannot explain product-level profitability.
Dispatch Delays
Finished goods stock reconciled manually. Dispatch team does not know which batches passed QC. Customer delivery promises are missed.
How These Problems Compound →
BOM Error
Wrong component in BOM
Wrong Materials Issued
Stores issues incorrect part
Production Stoppage
Line halts mid-run
Rush Procurement
Emergency PO at premium cost
Cost Overrun
Standard cost variance spikes
Customer Penalty
Late delivery penalty invoked
Sales Order to Dispatched Goods — End-to-End Traceability
From customer order to delivery, every material movement, production step, and quality check is linked — giving you full batch traceability and real-time cost visibility.
Everything Your Manufacturing Business Needs
All modules ship pre-configured for your industry. Connected, maintained, and supported by a single team.
How the Modules Connect
Module Spotlight
Production Planning
Feeds Bill of Materials (BOM) with: Work orders
Bill of Materials (BOM)
Multi-level BOM with engineering change management and version control.
- Multi-level BOM explorer
- Engineering change notice workflow
- BOM version comparison
Production Planning
MRP-driven production orders linked to sales orders with capacity check.
- Sales-order-driven MRP
- Work order scheduling
- Capacity vs load view
Raw Material Inventory
Batch-controlled inventory with real-time issue-to-production and GRN.
- Batch & lot traceability
- Auto reorder from MRP signal
- Warehouse bin management
Quality Control
In-process and finished goods QC with defect capture and CAPA management.
- Inspection plan per product
- Defect classification & Pareto
- CAPA tracking to closure
Purchasing
MRP-generated purchase requisitions with supplier rate contracts and PO approval.
- MRP-triggered requisitions
- Supplier scorecard
- 3-way PO/GRN/invoice match
Sales & Dispatch
Sales order management, delivery note generation, and dispatch tracking.
- Order-to-delivery tracking
- QC-cleared dispatch only
- E-way bill generation
Equipment & OEE
Machine utilisation, downtime logging, and preventive maintenance scheduling.
- OEE dashboard per machine
- Preventive maintenance calendar
- Downtime reason analysis
Cost & Financials
Standard costing with actual consumption variance and product-level P&L.
- Standard vs actual cost variance
- Product-level contribution
- COGS posting from production
Manufacturers Usually Need More Than the Shop Floor
This ERP covers production, quality, and cost — but most manufacturers run it alongside these Zopkit products for the full back-office picture.
Without It vs. With It
The same operation, before and after — in the terms your team actually uses.
BOM Management
Excel; engineering changes not tracked
Multi-level BOM with ECN version control
Production Scheduling
Board in factory; no system
MRP-driven work orders with capacity check
Quality Data
Paper registers; root cause guesswork
Digital QC linked to batch; Pareto analysis
Stock-out Prevention
Manual reorder from gut feel
MRP-triggered reorder from live sales orders
Product Costing
Annual standard; variance unknown
Actual consumption variance captured per batch
Your Path to Go-Live
A structured, supported implementation — not a DIY project.
Week 1
BOM & Item Master
Week 2
Production Planning
Week 3
Inventory & Stores
Week 4
Quality Control
Week 5
Purchasing & Sales
Week 6
Costing & Go-Live
- Item master import
- Multi-level BOM creation
- Unit of measure mapping
- Work order templates
- Routing & operations setup
- Capacity calendar
- Opening stock import
- Bin & batch structure
- Issue & GRN workflows
- Inspection plan per product
- Defect code library
- CAPA workflow configured
- Supplier & customer master
- MRP purchase requisition flow
- Sales order & dispatch
- Standard cost upload
- OEE dashboard live
- Full production cycle tested
Week 1
BOM & Item Master
- Item master import
- Multi-level BOM creation
- Unit of measure mapping
Week 2
Production Planning
- Work order templates
- Routing & operations setup
- Capacity calendar
Week 3
Inventory & Stores
- Opening stock import
- Bin & batch structure
- Issue & GRN workflows
Week 4
Quality Control
- Inspection plan per product
- Defect code library
- CAPA workflow configured
Week 5
Purchasing & Sales
- Supplier & customer master
- MRP purchase requisition flow
- Sales order & dispatch
Week 6
Costing & Go-Live
- Standard cost upload
- OEE dashboard live
- Full production cycle tested
Go-Live
Impact You Can Put on a Slide
Benchmarked against customers in their first year. Results typically visible within the first 90 days.
"Our BOM was wrong in 23% of lines — we only discovered this after a major customer rejection. After implementing the ERP with proper ECN workflow, our first-pass quality rate went from 81% to 96% in one quarter. The OEE dashboard alone recovered two full production shifts per month."
Component Manufacturer
Plant Head, 2-plant precision engineering business
320 SKUs, 2 plants