BoSS
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Manufacturing
From BOM to finished goods — production planning with process checkpoints.
The Manufacturing module brings structure to your production floor. Bill of materials, production orders, job work, quality gates, and actual costing — connected to inventory, procurement, and finance in a single system.
What this module solves
Indian manufacturing businesses face a unique challenge: managing production with a mix of in-house processes and job work, dealing with variable raw material quality, and tracking costs accurately when overheads are shared across products. Most manufacturing systems are either too simple (just BOMs and orders) or too complex (designed for automotive-scale operations).
The Manufacturing module is built for the 50-5000 crore Indian manufacturer. It handles the realities of Indian production — job work tracking, quality issues at every stage, scrap management, and the constant pressure to know actual product costs rather than relying on standard assumptions that were set two years ago.
Because MFG connects directly to Inventory (for material), Procurement (for shortages), Warehouse (for finished goods), and Finance (for costing), there is no data re-entry, no reconciliation gap, and no month-end scramble to calculate production costs.
Without this module
Production starts and discovers a critical raw material is short — halting the line and scrambling for emergency procurement at premium rates.
Job work material is sent out without proper tracking. Reconciliation of returns is approximate, hiding processing losses worth lakhs.
Product costing uses standards from last year. Actual costs are unknown until Finance does a quarterly analysis — too late to adjust pricing.
Quality rejections at final inspection waste an entire batch because there were no in-process checkpoints to catch the defect early.
Scrap is unquantified. Nobody knows the actual yield rate or how it compares to the BOM standard. Improvement efforts have no baseline.
Core capabilities
1
Bill of Materials (BOM) Management
Define multi-level BOMs with raw materials, sub-assemblies, and consumables. Each BOM carries quantity ratios, scrap allowances, and alternate material options. BOMs version-control changes with effective dates.
2
Production Order Management
Create production orders from BOMs with planned quantity, start date, and target completion. The system checks raw material availability and flags shortages before production begins. Track actual vs. planned output.
3
Process Routing & Work Centres
Define manufacturing routes — the sequence of operations a product goes through. Each operation maps to a work centre with capacity, cycle time, and setup time. Routing drives scheduling and cost accumulation.
4
Raw Material Issue & Consumption
Issue raw material to production orders from inventory. Track actual consumption against BOM quantities. Over-consumption triggers alerts and requires reason codes. Under-consumption is recorded as yield improvement.
5
Quality Checkpoints
Insert quality inspection stages at any point in the production process — incoming material, in-process, and final inspection. Each checkpoint has defined parameters and tolerance limits. Production proceeds only after quality clearance.
6
Job Work Management
Manage outsourced manufacturing processes. Track material sent to job workers, monitor progress, reconcile received goods against dispatched material, and account for job work charges. The entire chain from issue to receipt is documented.
7
Production Costing
Accumulate costs as production progresses — raw material at actual issue cost, labour from time tracking, overheads from allocation rules. Final product cost reflects actual production economics, not standard assumptions.
8
Finished Goods Receipt
Completed production enters inventory as finished goods with full cost attribution. Batch numbers and quality certificates are attached. The moment FG is received, it is available for sales order fulfilment.
9
Scrap & Waste Tracking
Record scrap generated during production with reason codes. Track scrap percentages against BOM allowances. Recoverable scrap is valued and returned to inventory. Non-recoverable scrap creates disposal records.
10
Production Planning Dashboard
View all active production orders, their stage, completion percentage, and bottleneck indicators. Plan production schedules considering work centre capacity, material availability, and delivery commitments.
Key workflows
1
Production Planning to Material Issue
A production order is created from a BOM. The system explodes the BOM to determine raw material requirements. It checks inventory for availability and flags shortages. Available material is reserved. Shortages trigger purchase indents. Once material is ready, issue slips are generated for the production floor.
2
Job Work Order to Receipt
Material that needs external processing is dispatched to the job worker with a challan. The job worker processes the material and returns finished or semi-finished goods. The system reconciles returned quantities against dispatched quantities, records processing losses, and books job work charges.
3
Quality Checkpoint to Approval
At each quality gate in the production process, inspectors record measurements against defined parameters. Items within tolerance pass to the next stage. Items outside tolerance are flagged for rework, downgrade, or rejection. Quality data accumulates to give a process capability profile.
4
Cost Accumulation to Finished Goods
As production progresses, costs accumulate against the production order — material at actual issue cost, labour from time records, overheads from allocation. When finished goods are received into inventory, they carry the full actual cost, giving accurate product profitability analysis.
Who benefits
Production Manager
Production scheduling with material availability visibility. No more starting a batch only to discover a critical component is missing. Capacity planning across work centres prevents bottlenecks.
Quality Head
Structured quality checkpoints with data capture. Trend analysis on rejection rates by product, process, and operator. Quality costs are quantified, not estimated.
Plant Head
Dashboard view of all production activity — orders in progress, machine utilisation, output rates, and yield metrics. Data-driven production meetings instead of anecdotal reporting.
Cost Accountant
Actual production costs calculated automatically. Variance analysis between standard and actual costs by material, labour, and overhead. Product costing that reflects reality.
Dashboards & reports
Production Order Status Board
All active production orders with current stage, completion percentage, planned vs. actual output, and expected completion date.
Work Centre Utilisation
Capacity utilisation by work centre with setup time, productive time, idle time, and maintenance downtime breakdown.
Yield & Scrap Analysis
Actual yield vs. BOM standard by product and batch. Scrap percentages with reason code Pareto analysis.
Job Work Tracker
Material with job workers, ageing, expected return dates, and reconciliation status. Identify delayed returns and pending charges.
Production Cost Variance
Standard vs. actual cost breakdown by material, labour, and overhead for each production order. Highlights cost overruns for investigation.
Works with
Inventory
Raw material is issued from Inventory to production orders. Finished goods receipt adds to Inventory stock. BOM explosion checks component availability across all inventory locations.
Procurement
Material shortages identified during production planning trigger purchase indents automatically. The procurement team sees the production schedule and plans material arrival to prevent line stoppages.
Warehouse Management
Finished goods receipt triggers putaway instructions in the warehouse. Raw material issue from specific bin locations ensures FIFO compliance at the production floor level.
Finance & Accounting
Production costs — material, labour, overheads — post to the correct accounting heads. WIP valuation, FG costing, and variance analysis data flow into financial reports.
Recommended for
Discrete manufacturersProcess industriesJob shop operationsAssembly unitsCompanies with job work outsourcingPharmaceutical productionFood & beverage processingTextile and garment manufacturers
Frequently asked questions
Can BoSS handle both discrete and process manufacturing?
Yes. Discrete manufacturing with BOMs and work orders, and process manufacturing with batch formulas, yield tracking, and co-product/by-product management are both supported. The module adapts to your manufacturing type.
How does the system handle BOMs with sub-assemblies?
Multi-level BOMs are fully supported. A finished product BOM can reference sub-assembly BOMs, which in turn reference raw materials. Production planning explodes the entire BOM tree to determine total material requirements across all levels.
Can we track rework and reprocessing?
Yes. Items rejected at quality checkpoints can be routed to rework orders. Rework orders track additional material and labour consumed. The total cost of the reworked item includes both original and rework costs.
How does job work material reconciliation work?
When material is sent to a job worker, the system tracks the expected return based on conversion ratios. On receipt, actual quantities are compared against expected. Differences are recorded as processing loss (within tolerance) or raised as exceptions (beyond tolerance).
Does the module support production scheduling across multiple shifts?
Work centre capacity is defined by shift. The scheduling engine considers shift timings, break times, and maintenance windows. Production orders can span shifts, and handover notes capture in-progress status for the incoming shift.
See how Manufacturing fits your operations
From a single product line to a multi-plant operation — bring data-driven discipline to your production floor.