erp solution for manufacturing industry

MANUFACTURINGINDUSTRY SOLUTION

ONTally.ERP 9Tally.ERP 9

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Introduced By

Overview of Project

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Sales & Marketing

Maintenance

Accounts

Purchase

Stores

Production

QualityPayroll

The following departments are

chosen for automation and the processes:

General Flowchart of Process for the Department - Purchase General Flowchart of Process for the Department - Purchase


Quality Assurance

VendorStores

AccountsRaw Material & Finished Goods Inspection

Clearance of Payment to Vendor

Invoice Payment

Raise P.O.Raising Indent Raising Indent

Send GRN / Invoice& QA Report

Raise Debit Note for Rejected Goods

Supply of Goods and InvoiceSend Back Rejected Goods

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PurchasePurchase

No. Document Title Owner Department Tally.ERP 9 Customizable

1 PURCHASE INDENT STORES NO YES

2 PURCHASE ORDER – LOCAL PURCHASE YES YES

3 PURCHASE ORDER – IMPORT PURCHASE YES YES

4 PURCHASE ORDER – CAPEX PURCHASE YES YES

5 JOB WORK ORDER (IN-OUT) PURCHASE YES YES

6 GATE ENTRY- QC (INSPECTION REPORT) G.R.N. QC and STORES YES YES

7 DEBIT NOTE FOR REJECTED MATERIAL PURCHASE YES YES

8 BILL PASSING MEMO (FOR RELEASING PAYMENT) PURCHASE YES YES

9 PAYMENT ADVICE NOTE (PAYMENT VOUCHER) ACCOUNTS YES YES


List of Purchasing System DocumentsList of Purchasing System Documents

No. Report Title Report Description Tally.ERP 9 Customizable

1 Indent Report Information on indents raised item wise/ sub-department-wise (Raw Material / Packing Material etc.) NO YES

2 P.O. Report Check pending P.O. s for one or all vendors in a single screen YES YES

3 P.O. Report Check pending P.O. s for one or all Item wise in a single screen YES YES

4 Voucher Register Voucher Register YES NO

5 Gate Entry Register Gate Entry Register for all Materials (GATE ENTRY - QC PASSING - STORES ENTRY with GRN) NO YES

6 ROL /MOL Report Re-Order Level / Minimum Order Level monitoring for raising next P.O. YES NO

7 MRP Material Requisition Plan (Based On Actual Sale Orders And Expected Orders) NO YES


List of Purchasing System ReportsList of Purchasing System Reports


8 PP Report – RM - SUM Purchase Planning Report (Raw Material) – Summary NO YES

9 PP Report – RM - DET Purchase Planning Report (Raw Material) – Detail with P.O. Status NO YES

10 PP Report – PM - DET Purchase Planning Report (Packing Material) – Detail with P.O. Status NO YES

11 PP Report – SF - SUM Purchase Planning Report (Semi Finished Goods) – Summary (to plan RM requirement) NO YES

12 PC VS SC Report Purchase Cost V/s Standard Cost (To Check Historical Information) NO YES

13 Inflation Report Inflation Report (To Check Trend In Change Of Purchased Goods Prices) NO YES

14 PR – Supplier Wise Supplier Wise Purchase Report NO YES




15 OPR – PO Wise Outstanding Payment Report - PO Wise NO YES

16 OPR – Supplier Wise Outstanding Payment Report - Supplier Wise NO YES

17 Ageing Analysis Ageing Analysis – Payments NO YES

18 Stock Query Report History of all the parameters of a given stock item in a consolidated CARD like format YES NO

19 Vendor Evaluation Vendor Evaluation Report – for ISO Compliance ) No YES



Additional Additional Facility for the Facility for the

Process Process AutomationAutomation

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Security Module

Avoid Modification of P.O. at junior operator level

No Purchase Invoice to be created without PO and GRN REF

Purchase Bill Rate should not exceed PO Rate

Purchase Quantity shouldn’t vary beyond a certain variation than ordered (5% - 10%)

Approvals for variance in parameters by junior staff required before P.O. finalization. ( Depending on the item, value/quantity shouldn’t exceed a certain limit. If needed, it must be authorized by higher level mgmt.)

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Store DepartmentStore Department

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General Flowchart of Process for the Department - StoresGeneral Flowchart of Process for the Department - Stores

Inform MaterialAcceptance for Production

Issue Raw Material for Production

Issue Returnable Materialfor External Processing

Raw Material Inspection Report

Return Rejected Material

Incoming Raw Material Inspection

Purchase Production Process Vendor

QualityAssurance Material Supply Vendor

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StoresStores


1 Goods Receipt Note Stores/Purchase YES YES

2 Rejection Out (Challan Rej.) Stores YES No

3 Returnable Gate Pass (for material sent for repairing) Process Vendor NO NO YES

4 Returnable Gate Pass / Goods sent out for Job Work on Returnable basis Process Vendor YES YES YES

5 Non returnable Gate Pass Process Vendor YES YES

6 Issue Slip for Raw Material Production YES YES

7 Issue Slip for Consumables Production YES YES

8 Purchase Bill Pending Purchase Bill Pending Report YES NO


List of Store System Documents


List of Store System Documents


9 Returnable goods register (Repairing) Returnable Goods Tracking report. NO YES

10 Returnable goods register (Job Work) Returnable Goods Tracking report. YES NO

11 Register (Vertical Layout) Voucher Register Report YES NO

12 Register (Horizontal Layout) Voucher Register Report YES NO

13 Closing Stock Report Closing stock with Qty / Rate / Amt. YES NO

14 Material Issue Report/Consumption Material Issued - Department wisewith Qty / Amt. YES NO

15 Stock Item Stock Item Ledger Report YES NO

16 Ageing Analysis Stock Ageing Report YES NO

17 ABC Analysis ABC Analysis based on consumptionpattern (quantity-wise/value-wise) NO YES


GRN Security – 1 :

Qty variance between PO and GRN is acceptable under a certain limit (5%,10% etc.)

GRN Security – 2 :

Rate variance between PO and GRN where rate is higher than P.O. not to be accepted

Additional Additional FeaturesFeatures

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Production DepartmentProduction Department


General Flowchart of Process for the Department – ProductionGeneral Flowchart of Process for the Department – Production

QualityAssurance

Stores

SalesRaise P. O.

Issue Raw Material

Finished Goods Testing1

3

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ProductionProduction


1 Production Entry of Finished Goods Planning /Prod Dept. YES NO

2 WIP Stock Entry (Based on Physical /Checking of Goods wherever applicable) Planning No Yes


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List of Production Department Documents

No. Report Title Report Description Tally.ERP 9 Customizable1 WIP Stock Report Semi Finished goods under process No Yes

2 Finished Stock Report Finished Goods To be recorded Location Wise No Yes

3 In Process Batch Report Semi Finished goods under process (RM to SF conversion) No Yes

4 Batches Under Filling Finished goods under process (SF to FG completion) – allocated to specific Work Order/ Batch / Stage / Recipe No Yes

5 Yield & Loss Report Actual consumption of material for a given process / recipe No Yes

6Excess / Under Consumption Report

Finished goods under process (SF to FG completion) – allocated to specific Work Order/ Batch / Stage / Recipe No Yes

7 Batch Cost Report - SF Semi Finished goods under process – allocated to specific Work Order/ Batch / Stage / Recipe etc. No Yes

8 Batch Cost Report - FG Finished goods after processing - allocated to specific Work Order/ Batch / Stage / Recipe etc. No Yes

9 Production Entry Register

Finished goods after processing - allocated to specific Work Order/ Batch / Stage / Recipe etc. Yes No


List of Production Department Reports


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Negative Stock SecurityMaterial Issue not allowed when Stock is Negative

Additional Additional feature for thefeature for the

ProcessProcessAutomationAutomation

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Quality Assurance DepartmentQuality Assurance Department


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General Flowchart for the Process – Quality AssuranceGeneral Flowchart for the Process – Quality Assurance

Production

Raw Material Vendor

Quality Inspection

Material as per P.O.

Store accepted Raw Material and Finished Goods

Stores

1

3

2 QualityQualityAssuranceAssurance


1 Quality Inspection for Raw Material QC No Yes

2 Planning /Prod Dept. QC No Yes


List of Quality Assurance System DocumentsList of Quality Assurance System Documents


1 Inspection Report – RM Inspection Status (Completed / Pending) report for RM No Yes

2 Inspection Report – RM Inspection Status (Completed / Pending) report for FG No Yes


List of Quality Assurance System ReportsList of Quality Assurance System Reports

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Sales / Marketing Department


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General Flowchart for the Process – Sales / MarketingGeneral Flowchart for the Process – Sales / Marketing

Accounts Production

Stores / QA / DispatchClients

Raise P. O.

Raise P. O.

Deliver Finished Goods

Deliver Material as per P.O.

Rejection of unacceptable material

Invoice Payment

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SalesSales


1 Delivery Order (SO) Sales Yes Yes

2 Dispatch Note (DN) Sales Yes Yes

3 Commercial Invoice Sales Yes Yes

4 Excise (TAX) Invoice Sales Yes Yes

Export Documentation

Pre-Shipment Reports

5 Proforma Invoice Sales Yes Yes

6 Packing List Sales No Yes

7 Letter for Bank Collection Sales No Yes


List of Sales System DocumentsList of Sales System Documents

No. Document Title Owner Departme Tally.ERP 9 Customizable

8 ARE 1 Sales No Yes

9 Bank Certificate Sales No Yes

10 Appendix Sales No Yes

11 Bill of Lading Sales No Yes

12 Pre Shipment Information Sales No Yes

13 Certificate of Origin Sales No Yes

14 ECGC Sales No Yes

15 Exchange Copy (1st and 2nd) Sales No Yes

Post-Shipment Reports


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16 Commercial Invoice Sales Yes Yes

17 Packing List Sales No Yes

18 ARE 1 Sales No Yes

19 Many More Relevant Documents for Export are available Sales

20 Credit Note (Sales Return) Client No Yes




1 Pending Delivery Order Report Pending Sales order with Client wise / Item wise Details Yes Yes

2 Form Collection Report C/H Form Report Yes Yes

3 Form Collection Reminder Reminder Letter for C/H form Collection No Yes

4 Sales Analysis Product-wise

Product Group Sales Yes Yes

Product Level Sales Yes Yes

Product Shade Level Sales Yes Yes

SKU Level Sales Yes Yes


List of Sales System ReportsList of Sales System Reports


Sales Analysis Customer-wise

Customer Wise Sales Report Yes Yes

Customer Month Wise Volume Sales Report Customer Yes Yes

Month Wise Value Sales Report Yes Yes

5. Budget AnalysisSales Budget Based On Parameters Like Salesperson,Area, Product Etc.

Report - Budget Vs Actual – Volume No Yes

Report - Budget Vs Actual - Value No Yes




6 O/S ANALYSIS Outstanding Collection Report - Invoice Wise Yes Yes

Outstanding Collection Report - Customer Wise Yes Yes

Ageing Analysis Yes Yes

Month Wise Receivable Analysis No Yes

7 Dispatch Schedule Report Dispatch Planning Schedule Report No Yes


List of Sales System ReportsList of Sales System Reports

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Maintenance Department


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General Features For - Maintenance DepartmentGeneral Features For - Maintenance Department

General Scope of Activities of Maintenance Department

Keep the machines and equipments in production dept.

fit for purpose all the time

Provide maintenance servicesTo all the other departments

Maintain Own Inventory of Spares etc.

MaintenanceDepartment


1 Receive material from stores in maintenance.Godown Maintenance No Yes

2 Issue material to maintenance Maintenance No Yes


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List of Maintenance System DocumentsList of Maintenance System Documents


1. Inventory Inventory Report of Spares Yes Yes


List of Maintenance System Reports

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Accounts Department


What Accounts Department Does?

The simple figure above indicates that the reflections of almost all interdepartmental interactions reflect in accounts.As we use Tally, we get the earlier mentioned reports as well as money value of these transactions.

Accounts department ultimately generates two important types of reports:1. MIS and2. STATUTORY

AllDepartmentGeneral General

Features for Features for Accounts Accounts

Department Department

AccountsDepartment


1 Statutory Compliance TDS/TCS Management (Salary and Non Salary Yes Yes

VAT management Yes Yes

CST management with Form Receivable Status Yes Yes

Service Tax Yes Yes

Excise Returns Yes Yes

2 Other Reports Fixed Assets Register

Bank Reco Module Yes No

Dash Board No Yes

Remote Access With Edit Features Yes No


List of Accounting System Reports

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Payroll Department


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Maintain Records of all the employees in tandem with HR.

Calculate proper payments towards salaries and statutory deductions.

Disburse the salaries and statutory payments.

Comply with the statutory requirements like PF and PT returns etc.

General General Features for Features for

PayrollPayrollDepartment Department

Role of Payroll :


1. Integration with Present HR Attendance Software No Yes


List of Payroll System Documents


1 Salary Slip and Register Yes No

2 Bank payment advice for salary payment Yes No

3 Department wise monthly salary summary Yes No

4 Gratuity Cont. Liability Yes Yes

5 Leave Record Module Yes Yes

6 Bonus - Report & Certificate

7 Other Reports

a. Provident Fund Yes No

b. Professional Tax Yes No

c. ESIC Yes No

d. TDS Yes


List of Payroll System ReportsList of Payroll System Reports

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