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Essence ERP
01Production

Manufacturing ERP: production control that survives contact with the shop floor

In one line
Every work order, machine and rupee of material cost in one place
Built for
Manufacturing & Job Work
Core
ERPNext, open source
Typical go-live
3 to 4 months

Most manufacturing ERPs are accounting systems with a production module bolted on. Plans assume infinite capacity, job cards live on paper, and costing turns accurate two months after the goods shipped. Essence ERP inverts that: the production model comes first, the ledger follows.

Material requirements come from live stock and open orders. Schedules respect the machines you actually have. Job cards write back the time and material they consumed, so planner, supervisor and accountant share one set of numbers.

Request a demoSee your industry
Essence ERP manufacturing dashboard showing work order status, machine utilisation and production output
Production control tower — work orders, utilisation and output against plan
25%
Higher throughput from better planning
18%
Less material waste
75% → 95%
On-time delivery
60% → 85%
Machine utilisation
02What is in it

Every work order, machine and rupee of material cost in one place

Plan against real capacity, run the floor on digital job cards, cost every finished unit accurately. Multi-level BOM to dispatch.

01

The BOM is your cost model, not a parts list

Bills of material nest to unlimited depth: an assembly explodes to the last fastener without a spreadsheet per sub-assembly. Cost rolls up the tree the moment a rate changes. Approved alternatives carry their cost delta, so procurement switches grade in a shortage without stopping the line.

  • Unlimited depth, exploded and indented views
  • Cost rollup on any rate change
  • Approved alternatives with cost delta
  • Routing lives on the BOM
  • Scrap and by-product at every level
Multi-level bill of materials in Essence ERP with exploded sub-assemblies and live cost rollup
Multi-level BOM with cost rolling up the tree as material rates change
02

MRP that reads live stock, not last month's

One run reads confirmed orders, forecast, stock, open purchase orders and supplier lead times. Safety stock follows consumption history and lead-time variability, not a number typed in once in 2019. Every receipt scores the supplier on on-time delivery, short supply and rejections.

  • One run: orders, forecast, reorder levels
  • Safety stock from lead time and consumption
  • Draft POs grouped by supplier
  • Supplier scorecards from receipt history
Material requirement planning run in Essence ERP netting demand against stock and open purchase orders
MRP netting confirmed demand against live stock and open purchase orders
03

Schedules built against the plant you actually have

The engine respects machines, tooling and skilled operators, batching similar jobs to cut changeovers without losing priority dates. When a machine drops or a rush order lands, reschedule in place and see which deliveries are now at risk. Your bottleneck becomes a number, not an opinion.

Includes

Machine, tooling and skill constraints · Setup time cut by intelligent batching · Reschedule in place, see the risk · Continuous bottleneck and utilisation analysis

04

Paper job cards record the plan, not the shift

Each operation carries its work instructions, quality specification and drawing; the operator starts and stops it from a tablet or shared terminal. Actual time, consumption and quality results are captured as the job runs — which is what makes the costing real, and lets supervisors watch run, idle, hold and rework without walking the floor.

  • Instructions and specs on every operation
  • Operator start/stop, real time captured
  • Issue and return booked to the job
  • Rework and quality hold visible, not hidden
  • Shared floor terminals and mobile
Digital job card in Essence ERP capturing operator time, material consumption and quality outcome
Digital job cards recording real time and real consumption on the floor
05

A batch cannot move while its inspection is open

Inspection plans attach to incoming material, in-process operations and finished goods, with parameters, tolerances and sampling rules set once per item. Every defect carries a classification and a cause, so Pareto over a quarter names the three types costing you most.

Includes

Incoming, in-process and final inspection · Tolerances with automatic pass/fail · Defect classification with root cause · Non-conformance tracked to closure

06

Material at the subcontractor is still your material

Anything out for plating, heat treatment or machining is tracked on challan from the moment it leaves, with the value sitting correctly on your books throughout. Rate contracts, expected yield and scrap allowance sit per vendor and process, so short returns surface immediately rather than at year end.

Includes

Outward and inward challans, GST compliant · Live balance with each subcontractor · Expected yield and scrap per process · Automated reconciliation statements

03The sequence

How a job moves through it

Each stage hands the next one its inputs. Nothing is retyped along the way, and every step leaves the record it was worked from.

  1. 01

    Sales order

    Confirmed demand, delivery dates, specifications

  2. 02

    Production plan

    MRP nets demand against stock and open POs

  3. 03

    Purchase

    Shortfalls drafted as POs by supplier

  4. 04

    Work order

    BOM and routing explode into operations

  5. 05

    Job card

    Operators execute; real time and consumption

  6. 06

    Quality

    Inspection gates the next stage

  7. 07

    Dispatch

    Packing list, invoice, e-way bill

04Integrations

Fits the systems you already run

Nothing here requires replacing the rest of your stack. Tally runs in parallel through transition, CRM and e-commerce push orders in, and GST filing, e-invoicing and e-way bills go straight to the portals.

Biometric and RFID attendance, weighbridges, barcode printers and IoT sensors feed the system. Where a machine speaks Modbus or OPC-UA we read run state and cycle counts directly, so utilisation is measured rather than remembered.

05Outcomes

What changes in the first year

Six to twelve months after go-live, the gains come from visibility and enforcement, not from working harder:

  • Planners stop rebuilding the schedule in Excel
  • Costing closes with the month, not six weeks later
  • Shortages surface at planning, not at the workstation
  • Rework and scrap become measured and attributable
  • Machine utilisation gets a number and an owner
  • Delivery dates come from capacity, not optimism
06Questions

The ones that come up first

We do both make-to-order and make-to-stock. Does that work?
Yes. Item-level policy decides whether demand comes from a confirmed sales order or from a forecast and reorder level. Both run through the same planning run and the same work orders.
Our operators are not comfortable with computers.
Job card execution is built for a shared terminal: large touch targets, scan to start, about two actions per operation. Where even that is too much, a supervisor runs the terminal for a line and the data still beats paper comfortably.
07Who runs it

Industries this product was shaped by

The workflows in it came from these businesses, and each of them reads the system slightly differently.

All industries
01

Manufacturing & Job Work

Plans built on real capacity, job cards that record what actually happened, costing that closes with the month.

Industry
08Elsewhere in the range

Other products, same core

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Supply Chain

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Bin-level inventory with QR scanning, guided putaway, wave picking, FEFO enforcement and cycle counting that runs without shutting the warehouse.

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See it running on your own numbers

A demo on sample data proves very little. Send us a week of your real documents and the same screens come back with your business in them, before anyone signs anything.

Start a conversationBook 30 minutesor call +91 94298 76631