Smart Bill of Materials (BOM)

Build precise and flexible BOMs with complete control.

• Create multi-level BOMs for complex assemblies.
• Manage alternate grades and regrind usage in a single structure.
• Define separate BOMs for in-house and contract manufacturing.
• Use copy & variant templates to quickly generate color or product variants.
• Define layer-wise BOMs for multi-layer film and sheet products.

Streamline production setup, reduce duplication, and ensure cost accuracy.

Advanced Access Control

Protect data integrity and enforce secure access across your organization.

• Define role-based permissions for users and departments.
• Assign module-level and granular action rights to limit unauthorized changes.
• Control factory-level visibility for multi-unit companies.
• Enable VPN and IP-based restrictions for secure remote access.
• Ensure each user sees only relevant items, parties, and data for their unit.

Strengthen security, maintain accountability, and ensure compliance across all operations.

Smart Material Requisition & Issue

Automate material planning, requisition, and issue with complete traceability.

• Generate auto material requisitions directly from the Bill of Materials.
• Substitute alternate materials or regrind automatically during shortages.
• Factor in runner and pinch-off weights for precise issue quantities.
• Account for on-machine inventory before issuing new material.
• Ensure material is issued only after previous consumption is recorded.
• Maintain FIFO discipline and issue polymers in packing-size multiples.
• Use QR-code-based material issue for faster and error-free transactions.

Eliminate manual slips, improve accuracy, and save valuable production time.

Smart Production Management

Digitize your shop floor with real-time, automated production management.

• Consolidated screen for multi-machine entry and quick data capture.
• Auto-transfer of finished goods, rejects, and wastage to respective stores.
• Capture operator and QA personnel for full traceability.
• Auto-select moulds based on item and machine setup.
• Record processing parameters, wastage, and rejections in one view.
• Integrated online QA and tablet-based hourly data entry.
• Dashboard displays machine-wise performance & OEE metrics.
• Optional IoT device integration for live data capture.
• Generate machine history, shot count, and downtime reports.
• Manage family moulds, multi-process lines, and repairs-to-acceptance cycles.
• Supports all processes: Injection, Blow, ISBM, Stretch Blow, Compression, Roto, Film, Pipe, Lamination, Bag Making & more.

Gain total visibility, improve efficiency, and ensure accuracy from shop floor to dispatch.

Automated Production Control

Automate your production workflow from sales order to shop floor.

• Auto-generate work orders directly from sales orders.
• Create work orders for both finished items and in-house components.
• Assign machines, dates, and quantities for precise scheduling.
• Track production progress and balance using Work Order–based control.
• View pending work order reports for planning and prioritization.

Bridge sales and production seamlessly — eliminate manual coordination and improve delivery accuracy.

Production Efficiency & OEE

Measure, monitor, and improve performance across every machine and operator.

• Calculate OEE (Overall Equipment Effectiveness) and its key components — Availability, Performance, and Quality.
• Monitor machine efficiency and operator productivity in real time.
• Identify bottlenecks and losses to improve uptime and output.

Transform raw production data into actionable efficiency insights.

Secondary & Post-Moulding Processes

Extend ERP control beyond moulding — track every finishing and assembly step.

• Manage secondary operations such as wadding, flipping, pad printing, screen printing, UV printing, and labeling.
• Handle sleeving, assembly, and packaging within the same production workflow.
• Link secondary operations to production, costing, and dispatch for complete traceability.

Achieve end-to-end visibility — from moulding to final finished goods.

Smart Material Consumption

Track material usage with precision and automatic variance control.

• Consumption auto-calculated from the Bill of Materials (BOM).
• Monitor variance limits and trigger alerts for deviations.
• Adjust polymer consumption for actual moulding weight and wastage produced.
• Account for line rejections and material returned from production.
• View batch-wise consumption vs. standard reports for transparency.
• Calculate the true cost of material consumed in every production batch.

Improve accuracy, control wastage, and maintain real-time costing integrity.

Dealer Portal

• Clients / field sales team punch orders with ease on mobile. Data auto converted to Sales Order saving valuable man hours and reducing data entry errors+
• Portal provides client order status, analytics and other features

Smart Sales Processing & Invoicing

Streamline your entire sales cycle — from quotation to dispatch — with full automation and control.

• Centralized monitoring of sales order processing across multiple plants.
• Convert quotations to sales orders instantly; auto-generate internal SOs for inter-company supplies.
• Apply auto approvals using master rate lists and prevent outdated billing through rate expiry controls.
• Manage multi-schedule orders, attach client POs, specs, or drawings for easy reference.
• Allow dealers or field teams to punch orders via mobile portal; auto-convert data to sales orders.
• Ensure GST, HSN, and delivery-based tax automation with zero manual intervention.
• Enable QR-code-based invoicing, e-way bill, and e-invoice generation with digital signatures.
• Automate mailing/WhatsApp of invoices, COA, LR, and dispatch documents to clients.
• Control discounts, SKUs, and rate-based approvals for B2C and multi- location setups.
• Generate subsidiary invoices, OTIF, and sales dashboards by product, client, or plant.Simplify order-to-cash — faster billing, zero errors, and higher customer satisfaction.

Simplify order-to-cash — faster billing, zero errors, and higher customer satisfaction.

Export Documentation & Invoicing

Simplify export documentation and ensure compliance through automation.

• Integrate export documentation seamlessly with sales orders and invoices.
• Auto-calculate and record duty drawback and export incentives.
• Maintain complete traceability from order to shipment documentation.

Streamline export billing, save time, and eliminate manual paperwork.

Smart Material Planning (MRP)

Automate material planning based on delivery schedules and production demand.

• Generate material requirements from customer schedules or internal production plans.
• Convert in-house production items to bought-out items when required.
• Factor in minimum stock levels, pending purchase orders, and alternate grades in planning.
• Get daily alerts for materials falling below minimum stock limits.
• Auto-generate purchase requisitions with delivery schedules, saving time and ensuring timely availability.

Plan better, prevent shortages, and keep your production running without interruption.

Graphical Machine & Production Planning

Plan moulding, assembly, and secondary operations visually with ease.

• Use an intuitive graphical scheduling tool for moulding machine planning.
• Visually plan assembly and secondary production operations to optimize machine loading.
• Instantly identify overlaps, idle time, or capacity constraints through drag-and- drop scheduling.

Simplify planning, improve resource utilization, and enhance production visibility.

Vendor Portal

• Receive Advance Shipment Notice
• Vendors can raise ASN only against pending PO
• Single scan inward entry of material at gate and stores

Purchase Requisition to Order Processing

Automate procurement from requisition to vendor order with complete control and visibility.

• Release purchase orders with multiple delivery schedules and automated approvals.
• Check plant-wise inventory at PO release to prevent overstocking.
• Approve POs based on user rights, value, or hierarchy levels.
• Send email, WhatsApp, or SMS alerts to vendors instantly with attached drawings and documents.
• Maintain purchase registers, drill-down reports, and supplier performance analysis.
• Auto-calculate polymer discounts based on supplier MOUs.
• Attach vendor quotes for traceability and future reference.

Reduce manual effort, prevent errors, and strengthen vendor relationships through automated purchasing.

Real-Time Production Batch Costing

Get precise, real-time costing for every production batch.

• Calculate actual batch cost using real-time data on:
  • Power consumption
  • Direct manpower utilization
  • Landed cost of raw materials consumed
• Customize cost formulas to suit company-specific methods or parameters.

Achieve true cost visibility, accurate profitability, and smarter pricing decisions.

Quality Assurance & Inspection

Ensure product quality through standardized inspections and complete traceability.

• Perform incoming inspection of bought-out materials using user-defined standards.
• Generate Pre-Delivery Inspection (PDI) reports as per customer or internal standards.
• Place materials on HOLD status pending final approval or rejection.
• Capture in-process and line rejections during production.
• Record status changes as materials move from hold to accepted or rejected.
• Analyze item-wise rejections with reasons to identify recurring issues.

Strengthen quality control, minimize rejections, and ensure customer satisfaction.

Digital & Online Inspection

Digitize inspection and capture real-time quality data on the shop floor.

• Conduct online inspection of manufactured items during production.
• Record cavity-wise dimensions and observations directly into the system.
• Perform First Piece Inspection (FPI) to validate setup and process parameters.
• Capture processing parameters via tablet for speed and accuracy.

Eliminate manual recording, reduce errors, and ensure consistent product quality.

Customer Rejection & CAPA Management

Close the loop on quality issues with transparent CAPA tracking.

• Record customer complaints and corrective / preventive actions through an integrated CAPA portal.
• Allow clients to track complaint progress online for complete transparency.
• Maintain a knowledge base of past issues and resolutions for training and prevention.
• Capture internal manufacturing complaints and monitor resolution effectiveness.

Build a culture of accountability, learning, and continuous improvement.

End-to-End Traceability

Achieve complete forward and reverse traceability across your supply chain.

• Forward traceability: Track every product from Goods Receipt Note (GRN) to production batch to customer invoice.
• Reverse traceability: Trace from invoice back to batch, machine, production team, and raw material batches.
• Instantly identify sources of defects, verify compliance, and enhance audit readiness.

Gain total control and confidence — from raw material to finished goods.

FIFO Material Control

Ensure inventory accuracy and product traceability with system-enforced FIFO logic.

• Auto material requisition and issue to shop floor follow FIFO sequence.
• During production, auto consumption applies FIFO from material issued to machines.
• Dispatch and invoicing automatically pick materials on FIFO basis.
• QR-code-based issue and sales controls prevent new batches from bypassing FIFO rules.

Maintain stock integrity, optimize usage of older lots, and ensure full traceability.

Wastage & Regrind Control

Monitor and control wastage with automatic tracking of regrind generation and usage.

• Classify types of wastage for better analysis and reporting.
• Capture wastage and regrind generation during every production run.
• Auto-issue grinding material as per limits defined in the BOM.
• Track grinding consumption and blending with virgin material in real time.

Minimize material loss, optimize regrind utilization, and maintain accurate cost control.

Toll & Contract Manufacturing Control

Manage contract manufacturing with full control over material flow and accountability.

• Issue materials as per BOM, preventing excess dispatch and material loss.
• Auto-adjust raw material based on BOM, agreed burn loss %, and actual item weight.
• Handle contract manufacturing for clients as well as labour job orders to vendors.
• Generate comprehensive statements of raw material, consumption, and deliveries.
• Automatically prepare Annexure II and VI for statutory documentation.

Ensure transparency, prevent leakage, and maintain complete traceability in all toll operations.

Real-Time Inventory Tracking

Gain total visibility of your inventory at every stage of production and dispatch.

• Track inventory at each intermediate stage — semi-finished, WIP, and finished goods.
• Monitor wastage, regrind, and customer-owned stock on your shop floor.
• Maintain batch- and location-wise inventory with full FIFO and traceability.
• Access valuation, movement, and stock ageing reports for financial control.
• Reconcile physical vs. system inventory instantly.
• View machine-wise material availability and usage in real time.

Improve accuracy, reduce idle stock, and empower faster production planning.

QR-Code Material Tracking

Digitize every movement of material with QR-code-based tracking and control.

• Generate unique QR codes for each purchased packet or batch.
• Issue materials on FIFO and by requisition through quick QR scanning.
• Track inter-store transfers seamlessly using QR codes.
• Generate QR codes for each box packed for sales and dispatch.
• Enable scan-based invoicing to match goods with client orders.
• Simplify stock-taking and reconciliation through QR code scans.

Eliminate manual errors, speed up movement, and achieve 100% traceability.

Predictive & Preventive Maintenance

Plan, monitor, and analyze machine and mould maintenance with total visibility.

• Record consumables and spares used per machine with cost tracking.
• Maintain breakdown history by time, reason, and maintenance action.
• Schedule preventive maintenance using mould shot counts and machine hours.
• Receive SMS alerts for specific breakdowns or overdue maintenance.
• Maintain complete machine and mould maintenance history.
• Follow a structured daily, weekly, monthly, quarterly, and annual preventive plan with cost analysis.
• Get alerts for pending preventive maintenance to avoid breakdowns.
• Use the mobile maintenance app for quick logging and status updates.

Reduce downtime, extend equipment life, and control maintenance costs.

Automated Director Dashboard

Deliver daily business insights directly to management — automatically.

• Auto-email a one-page Director’s Report summarizing key daily metrics.
• View production efficiency per machine, major rejections, and breakdown summaries.
• Get a concise sales and purchase summary for the previous day.
• Ensure top management has actionable insights without logging in.

Stay informed, proactive, and in control — every single day.

Automated MIS & Daily Alerts

Empower every level of management with automated, insight-rich reports and alerts.

• Receive auto-emailed MIS reports tailored to each user’s role at day-end.
• Highlight key deviations like cavity variance, cycle time variance, and material consumption variance.
• Choose between detailed or consolidated formats based on responsibility.
• Access interactive dashboards and drill-down reports for deeper insights.
• View sales summaries by polymer grade, client, product, or plant.
• Generate profitability and performance analytics automatically.

Stay alert, informed, and agile — with timely data at your fingertips.

Integrated Accounting & Finance

Automate your financial operations with complete accuracy and control.

• Calculate MOUs, quantity-based, and special supplier discounts automatically.
• Generate GST reports and reconcile transactions seamlessly.
• Auto-create debit/credit notes for rate or quantity differences between PO and invoice.
• Get TDS deduction alerts and auto-generate adjustment vouchers.
• Access drill-down Trial Balance, P&L, and Balance Sheet instantly.
• Enforce credit control by blocking dispatches beyond approved limits.
• Auto-mail payment reminders and statements to customers.
• Generate bank payment lists with portal integration, auto-posting, and payment advice.

Simplify compliance, eliminate manual effort, and gain financial transparency.

Data Migration & System Integration

Seamlessly migrate your legacy data and connect PlastERP with existing systems.

• Import items, machines, moulds, suppliers, and customers directly from Excel into PlastERP.
• Export purchase (GRN) and sales invoice data to your financial or legacy accounting system.
• Continue maintaining accounts in your existing setup while PlastERP handles operations.

Ensure smooth transition, eliminate duplication, and enable hybrid ERP–finance operation.

Document Control & Audit

• Maintain and access master records connected to items, parties, machines, moulds
• Link and Upload original shipping bills, LRs and other documents to their respective transactions
• History of changes made to masters and transactions
• Auditors can post remarks online against specific document