ERP for Manufacturing Companies

MRP (Material Requirements Planning) is the production planning logic in a manufacturing ERP that automatically calculates what raw materials to purchase, in what quantities, and by when - based on the production schedule, existing inventory, open purchase orders, and Bill of Materials for each product. Without MRP, purchase decisions are made manually based on experience and visual stock checks - leading to both stockouts (material not ordered in time, stopping production) and overstocking (material ordered too early or in excess, tying up working capital). MRP eliminates both by calculating net material requirements mathematically and generating time-phased purchase requisitions. The accuracy of MRP depends on correctly configured BOM quantities, inventory records, and lead times.

A Bill of Materials (BOM) is the recipe for a product - a structured list of every raw material, component, and sub-assembly required to produce one unit, with their exact quantities. For a food manufacturer, the BOM for a specific product lists every ingredient and its quantity per kg of output. For an engineering components manufacturer, the BOM lists every raw material (bar stock, fasteners, coatings) and their quantities per piece. A multi-level BOM handles sub-assemblies - components that are themselves manufactured before being used in the final product. The BOM is the foundation of manufacturing ERP - it drives MRP calculations, production costing, and material issue from store to production.

Discrete manufacturing produces countable, distinct items - a ceramic tile, an automotive component, a garment. Each unit is identifiable and production output is counted in pieces. Process manufacturing produces goods that are measured by weight, volume, or length - paint, pharmaceuticals, chemicals, food products. Key ERP differences: Discrete ERP tracks work orders per unit or batch quantity, routes through defined operations, and records output in pieces. Process ERP tracks production batches with formula/recipe management, records output in kg or litres, handles variable yield (input quantity does not always equal expected output), and manages by-products and co-products. Many manufacturers have both - a ceramic tile manufacturer that also manufactures its own glaze has both discrete (tiles) and process (glaze) production in the same facility. Evolution Infosystem builds ERP systems that handle both production types.

A manufacturing ERP implementation timeline: small manufacturer (20-50 users, 4-6 modules) takes 6-10 months. Medium manufacturer (50-200 users, 8-12 modules with MRP and quality) takes 10-16 months. Large multi-plant manufacturer takes 15-24 months. Timeline drivers: number of product BOMs to configure (a manufacturer with 2,000 SKUs takes longer than one with 200), data migration complexity, number of integrations (Tally, GST portal, weighbridges), and the number of manufacturing locations. At Evolution Infosystem, each module goes live on staging every 4-6 weeks throughout the project, and we use a phased go-live approach - inventory and procurement first, then production management, then quality and reporting.

Yes - quality management is a core module in Evolution Infosystem's manufacturing ERP. The quality module covers: inspection plan definition (which parameters are tested, at which stage, with what acceptable limits and test methods), quality result recording (pass/fail/hold per parameter per batch), NCR (Non-Conformance Report) creation for failed inspections, CAPA (Corrective and Preventive Action) workflow for root cause resolution, quality hold workflow (held batches cannot be dispatched until QA releases them), and supplier quality rating based on incoming inspection results. Inspection is configured at three stages: incoming raw material, in-process (at defined production stages), and finished goods.

Yes. Evolution Infosystem's manufacturing ERP integrates with: weighbridges (truck weight capture on goods receipt and dispatch - weight transmitted directly to ERP via RS-232 or TCP/IP serial communication), barcode scanners (handheld scanners for goods receipt scanning, work order scanning on shop floor, finished goods labelling, and dispatch confirmation), label printers (barcode label and dispatch sticker printing triggered from ERP), and basic IoT sensors for machine downtime recording (production stoppage events captured via MQTT and logged against work orders). Weighbridge and barcode integration eliminates the manual transcription errors that are most common in raw material receipt and dispatch.

Manufacturing ERP development for ceramics, pharma, automotive, FMCG, engineering, chemical, and garment manufacturers - including MRP, multi-level BOM, shop floor work order control, quality management, procurement, production costing, and GST compliance.

Yes. Evolution Infosystem builds custom MRP engines for Indian manufacturers - calculating net material requirements from BOM explosion, existing inventory, open purchase orders, and configured lead times to generate time-phased purchase requisitions.

Yes. Evolution Infosystem builds Schedule M-compliant pharma manufacturing ERP with batch manufacturing records, FEFO inventory, multi-stage quality inspection, QA release workflow, and 21 CFR Part 11-compatible audit trails.

Yes. Evolution Infosystem integrates manufacturing ERP with weighbridges (RS-232 and TCP/IP), barcode scanners, barcode label printers, and basic IoT machine sensors for production stoppage recording.

35% average improvement in production efficiency across delivered manufacturing ERP projects - measured from baseline operational metrics (inventory accuracy, production schedule adherence, quality rejection rate) versus 90-day post-go-live performance.