Aluminium Foil Sector ERP

Built for aluminium foil rolling and converting, and for the process manufacturers around it — a plant where a jumbo roll becomes slit rolls, becomes a converted product, becomes a packed carton, and every one of those steps has to leave a number behind. Orders, buying, the floor, the godown, exports and the books, in one database.

In daily use at Dugar Polymers Limited, Rossari Biotech Ltd — Foil Division and Rockdude Impex Pvt Ltd, across EOU and non-EOU units with group-company reporting.

Nothing is bought without the approvals

The most-worked part of the system, and the reason a growing plant outgrows a simpler ERP.

• Approval slabs by value — up to a limit, one named approver; above it, another, and so on, each drawn from the user master
• The requisition carries a rate, not just a quantity — averaged from what that item has cost before, and typed in only where there is no history
• The value of the requisition decides how many approvals it needs, and they are taken in sequence: the lower slab clears it, then it opens for the next
• Edit a requisition and its approvals are gone — every one of them, so an approved document cannot be quietly changed after the fact
• A purchase order takes the same route, and reaches GRN only once it is fully approved
• Reports show how many approvals, by whom, when, and how many are still pending
• Short close on a purchase order, keeping the balance quantity against each item
• Rejection quantity captured at GRN, and a PO that a GRN already references cannot be edited — a balance beyond tolerance means a new PO

Production, driven by the bill of materials

• BOM masters for finished goods and semi-finished goods, versioned — production runs on the current version or on a named older one, deliberately chosen
• Production order against machine and operator, listing finished goods and quantities in boxes, with the BOM version captured into the order as it stood
• Floor requisition raised against the production order — raw and packing material arrive already selected at BOM quantity, and the machine with them; quantities stay editable
• Production and packing entries both work off the production order, taking the machine and the BOM version from it
• Once material has been issued against a floor requisition, that requisition is frozen
• Production order close and short close, with a pending-quantity status report
• Bill of requirement and production schedule — orders on hand against stock on hand
• Machine operator master; down time entered with reasons and analysed by reason and by machine
• BOM incomplete and BOM not found reports — the two things that quietly break a BOM-driven plant

Reversals that respect the stock

Cancelling a transaction in a manufacturing plant is not a delete. Each of these takes its own document number, values retrospectively, reverses only what is still in hand, and will not let stock go negative:

• GRN reversal — selected items only, taking raw and packing material back out
• Production reversal — semi-finished stock down, raw and packing material back onto the floor
• Packing reversal — finished goods down, semi-finished and packing material back
• Sales cancel — the whole invoice marked cancelled and excluded everywhere in the software, with the stock returning to godown at its own cost

The audit trail

• A separate module for viewing the trail, holding the changes made through the financial year
• Watched documents: customer and supplier masters, item master, purchase order, GRN, sales order and sales invoice
• Watched fields: payment terms, bank details, item code, group, unit and pieces per box — and on every document, changes to line items, quantity, rate, date and entry number
• The report shows the value before the change, who made it and when; a line item added or removed is recorded with its code, quantity and rate
• Whole-entry deletions carry who deleted them and when
• Item names cannot be changed on edit at all; a master changes report covers the rest

Inventory, godown and floor

• Sub-godown, main godown and floor-wise stock for raw material, packing material, semi-finished and finished goods
• Roll and batch-wise movement, slitting, repairs both at godown and on the floor, stock JV between internal departments, and transfer to the dispatch godown
• Registers throughout — inward, requisition, issue to floor and its acknowledgement, back to godown, repairs, material used, slitting, production, store receipt
• Finished goods position: store receipt register, stock JV register, transfer-to-dispatch register, stock statement and stock register
• Bar code stickers, a difference register for standard against actual production, and slow and fast moving analysis
• GRN profitability — what a particular receipt actually earned

Selling, exporting and GST

• Pre-sales in its own right: sales inquiry, export inquiry, costing, offer and sample invoice
• Sales orders local and export, order merge, square-off and close
• Invoicing under current GST, customer and item-wise pricing fed in bulk from Excel, state-wise sales rate import, delivery challan, landing PI and commercial invoice
• Deemed export, merchant trade export and third-country merchant trade as document types of their own, not as adjustments to a local invoice
• Export documentation: performa invoice, custom invoice, packing list, custom certificate, covering letter and container-wise breakup, multi-currency throughout
• E-way bill generation for the portal, e-way bill number import, and e-invoice number import matched back to the invoices they belong to
• GSTR-1 Excel generation, and GST registers for sales, purchase, debit and credit notes
• Amazon sales invoices imported from their own file
• Ledgers and outstanding for foreign customers in their own currency, with shipping expense booked against the export or import invoice it belongs to

Buying and job work

• Purchase requisition for raw material, packing material and semi-finished goods
• Purchase inquiry, with inquiry mails going out to vendors from inside the software
• Purchase order, GRN with rejection quantity, purchase return and debit note
• Job work as a full sub-ledger: opening stock, challan entry, dispatch and transfer, with its own statement and reports

The books and the questions

• Full accounting — bank, cash and petty cash, expenses, journal, debit and credit notes, sales and purchase returns, bank reconciliation, TDS and TCS
• Trial balance with interactive edit, transfer JV, cash flow, fund flow, final accounts in T format
• Outstanding with aging analysis, adjustment and reminder SMS
• Dynamic sales analysis and dynamic inventory analysis — pick your own rows and columns rather than asking for a new report to be written
• Sales, purchase, payment and receipt analysis in rupees and in foreign currency; expense and balance analysis; monthly income and expense; over and below listings
• A report generator for what is left, and an Excel-for-Tally export where the accounts have to land in Tally anyway
• Tally import for accounts, opening balances and the daybook, when moving on to this from Tally

Everyday things

• Rights per user on every menu, several screens open at once, every report to Excel or PDF
• Reminders per user; e-mail and SMS from inside the software, including party-wise outstanding mail
• Data export and import between installations, daybook export, database and data-only backup
• Opening entries for accounts, stock, GRN, bank reconciliation and outstanding breakup, so the first year starts complete

Technical details

• Front end: Microsoft .NET (VB.NET) on Windows
• Back end: Microsoft SQL Server
• Output: native Excel and PDF, e-way bill and GSTR-1 files, SMTP mail, SMS