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Master Production Complexity and Drive Manufacturing Excellence

Integrated MRP, shop floor control, and HRMS on one platform. Real-time

visibility from raw material to finished goods.

Book Manufacturing Demo
Production Dashboard
Real-time monitoring
3 Active
Production Lines
82%
OEE Today
156
WIP Orders
94%
Capacity
Manufacturing Challenges We Solve

Address the critical pain points holding your production back

Production Scheduling Complexity

Coordinating machines, labor, and materials across multiple production lines while meeting delivery commitments creates bottlenecks.

Inventory & Material Shortages

Inaccurate demand forecasting and poor MRP execution lead to production delays and emergency purchasing at premium costs.

Quality Control Gaps

Tracking quality parameters across batches, managing rejections, and complying with standards without proper traceability.

Supply Chain Disruptions

Supplier lead time variability, transportation delays, and material quality issues halt production unexpectedly.

Skilled Labor Shortage

Difficulty finding and retaining skilled workers while managing shift schedules, overtime, and payroll complexity.

Equipment Downtime & Maintenance

Unplanned machine breakdowns reduce capacity utilization and create delivery delays with no preventive maintenance tracking.

Shop Floor Visibility Issues

Lack of real-time production status, work-in-progress tracking, and material consumption visibility delays decision-making.

Rising Manufacturing Costs

Material price volatility, energy costs, labor expenses, and waste without proper cost tracking and variance analysis.

How Our ERP Solves Manufacturing Challenges

Transform manufacturing operations with integrated systems that address root causes

Challenge

Production Scheduling Complexity

Manual scheduling leads to resource conflicts, machine idle time, and missed delivery dates.

Solution

Advanced Production Planning

  • MRP runs with material availability checks
  • Capacity-constrained scheduling by work center
  • Forward and backward scheduling algorithms
  • What-if scenario planning and simulation
Challenge

Inventory & Material Shortages

Poor visibility into material requirements causes stockouts and production stoppages.

Solution

Intelligent Inventory Management

  • Automated purchase requisitions from MRP
  • Raw material tracking with batch/serial control
  • Safety stock calculations by lead time
  • Vendor-managed inventory (VMI) integration
Challenge

Quality Control Gaps

Manual quality checks miss defects and lack traceability for root cause analysis.

Solution

Comprehensive Quality Management

  • In-process QC checks with SPC charts
  • Non-conformance reports with CAPA workflow
  • Rejection analysis and trend tracking
  • Vendor quality scorecards and audits
Challenge

Supply Chain Disruptions

No visibility into supplier performance and material pipeline creates uncertainty.

Solution

Supply Chain Resilience

  • Supplier lead time tracking and alerts
  • Multi-vendor sourcing strategies
  • Procurement analytics and spend visibility
  • Landed cost tracking for imported materials
Challenge

Skilled Labor Shortage

Inefficient workforce allocation and high turnover impact productivity.

Solution

Workforce Optimization

  • Shift management with skill-based allocation
  • Overtime calculation with dynamic rates
  • Training needs identification and tracking
  • Piece-rate payroll and incentive calculations
Challenge

Equipment Downtime & Maintenance

Reactive maintenance approach reduces equipment availability and increases repair costs.

Solution

Preventive Maintenance System

  • PM schedules based on machine hours/calendar
  • Breakdown maintenance requests and tracking
  • Spare parts inventory management
  • MTBF/MTTR analysis and reporting
Challenge

Shop Floor Visibility Issues

Production managers lack real-time insights into work order status and bottlenecks.

Solution

Real-Time Shop Floor Control

  • Work order tracking with operation completion
  • Material transfer and backflush automation
  • Labor timesheet integration for costing
  • OEE calculation and monitoring dashboards
Challenge

Rising Manufacturing Costs

No visibility into actual production costs vs. standard costs prevents optimization.

Solution

Cost Control & Analytics

  • Standard vs. actual cost variance analysis
  • Material waste and scrap tracking
  • Operation-wise cost center allocation
  • Profitability analysis by product line
Manufacturing ERP Capabilities

Comprehensive features for end-to-end production management

Production planning with MRP and capacity analysis
Work order creation from sales orders or forecasts
Subcontracting workflows with material issue tracking
Operation routing with time and cost center mapping
Production calendar with shift and holiday management
Capacity planning based on work center availability
Material transfer for work orders with backflush
Scrap reporting and variance tracking
Multi-level nested BOM structures with cost roll-up
BOM explosion for material planning and costing
Phantom assemblies for intermediate components
Alternate BOMs for material substitution
BOM versioning with engineering change control
Scrap percentage allocation by operation
Routing integration with operation sequences
BOM comparison and cost analysis tools
Work order generation with auto-material reservation
Operation-wise completion tracking and timesheet
Material consumption against planned quantity
Real-time WIP valuation and reporting
Work order status dashboard with filters
Batch production with multiple work orders
Rework and rejected quantity management
Work order costing with variance analysis
Parameter-based inspection criteria setup
Quality inspection for purchase, production, delivery
Acceptance sampling plans and sample size
Rejected material handling and vendor returns
Non-conformance reports with root cause
Corrective and preventive action (CAPA) tracking
Quality audit scheduling and checklists
Statistical process control (SPC) charts
Shift rostering with rotation schedules
Attendance marking via biometric/RFID
Overtime types with fixed/dynamic hourly rates
Skill matrix and worker allocation
Training compliance tracking for certifications
Payroll with shift allowances and incentives
Piece-rate calculation for contract workers
PF, ESI, TDS statutory compliance automation
Raw material procurement based on MRP
Multi-location warehouse management
Batch/serial tracking with shelf-life alerts
FIFO/LIFO/Moving average valuation methods
Stock transfer between production units
Material request to purchase order workflow
Supplier performance and delivery tracking
ABC analysis and slow-moving inventory reports
Manufacturing ROI Impact

Real impact on your bottom line with data-driven manufacturing operations

30%
Improvement in production efficiency through optimized scheduling
50%
Reduction in material wastage with MRP-driven procurement
40%
Faster quality issue resolution with traceability
25%
Labor cost optimization via automated attendance-payroll integration
Success Stories

From production chaos to operational excellence in 6 months

“Production planning and BOM control brought complete discipline to our shop floor. WIP visibility helped us cut rework by 18% within six months.”
Rohit Agarwal, Director – Shree Balaji Auto Components

"Real-time inventory visibility eliminated our stockout problems during festival season. Our revenue increased 23% YoY."
Mr. Sumeet Gupta, CEO – Prakash knitting Industries

The Results
OEE 65% → 82%
Equipment Effectiveness
35%
WIP Reduction
99%
On-Time Delivery

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+91 8429025976 sales@opticode.in