ERP for manufacturing. BOM to dispatch, with variance and job work reconciled as you go.
From bill of materials to dispatch, with variance and job work reconciled as you go instead of at the quarter-end.
Industry pack readyHow does Kinnow help a manufacturer? The bill of materials, the work order, the material issued and the finished lot sit in one record, so the cost of a run reaches the ledger and the gap between planned and actual material shows up the week it happens, not at the costing review. Nothing is filed, paid or posted without a person.
Your business in one paragraph
A plant turns a purchase commitment into a shipped batch. Material comes in against a purchase order, goes out to the line against a work order, some of it goes to a job worker and comes back, and the finished lot is costed and dispatched. The owner's worry is rarely the machine; it is the paper around it: what the BOM says, what was actually issued, what is lying with a subcontractor, and what the planner promised a customer.
Material drifts from the BOM
Actual use creeps above plan and nobody sees it until a costing review weeks later.
Material out with job workers
Challans and the quarterly ITC-04 are reconciled by hand, and the stock at the job worker is nobody's number.
A whiteboard for capacity
A rush order breaks the schedule because nobody could see the load on each work centre.
Send us one BOM and one work order and we will show the variance on your own numbers.
How your month runs on Kinnow
This is demand to dispatch, with the buying and job-work loops that sit under it.
| # | Step | Who | Application | Where a person signs |
|---|---|---|---|---|
| 1 | Order received; credit check holds it if the customer is over limit | Sales manager | Sell | Credit hold cleared by a person |
| 2 | Advisory MRP (material requirements planning) works through the BOM against stock and open orders and suggests what to make and buy | Production planner | Make | Planner confirms; nothing is released automatically |
| 3 | Requisition, purchase order, supplier qualified before release | Procurement officer | Buy | Purchase order above 5,00,000 needs approval |
| 4 | Material received; inbound QC inspection created on acceptance; failures raise an NCR | Stores, QC inspector | Stock & Ship, Make | Disposition of an NCR approved |
| 5 | Work order released; the capacity board shows the load on each work centre | Production planner | Make | Run above 5,000 units needs approval |
| 6 | Material issued; operators start and complete operations at the terminal | Shop-floor operator | Make | Operator named on each operation |
| 7 | Job work: material goes out on a challan with its e-Way bill and comes back; the agent reconciles | Stores, job-work coordinator | Make, Comply | Short-close or write-off is a person's action |
| 8 | Work order completes; the cost of the run moves from WIP to finished goods in the ledger | Automatic | Account | Cost variance reviewed by finance |
| 9 | Scrap above the limit is flagged; write-offs go for approval | Plant head | Stock & Ship | Write-off above 1,00,000 needs approval |
| 10 | Dispatch, invoice, e-invoice and e-Way bill; month-end close | Accounts executive, CA | Sell, Comply, Account | Return and close signed by a person |
What the industry setup gives you
The ready-made setup for your industry (we call it an industry pack) is in the app today: 6 limits, 4 sign-off orders (who signs off, in order), 9 reports, 13 ready-made Ask Kinnow questions, 10 agents and 20 step-by-step routines. Figures are starting values you set.
| Limit or rule | What happens | Why it is there |
|---|---|---|
| Production run above 5,000 units | Needs approval | Commits material and machine time before anyone sees demand |
| Purchase order above 5,00,000 | Needs approval | Raw-material buying is where margin is set or lost |
| Stock write-off above 1,00,000 | Needs approval | Either a real loss or a stock error; both need a name against them |
| Manual journal above 5,00,000 | Needs approval | Moves the books without a source document |
| Scrap above 50 units on a work order | Warning | Scrap is material already paid for and thrown away |
| Credit limit above 10,00,000 | Warning | Credit is a decision, not data entry |
The routines include Demand to dispatch, Buying raw material, Enquiry to confirmed order, Stock count to write-off, Stock transfer between warehouses and Obligation to filed, beside month-end close, payroll and access requests.
Processes, built in
A full set of best-practice processes for your industry come switched on: who owns each step, which steps Kinnow enforces, and a clock on every hand-off between departments. Print any of them as an SOP.
Ask us to walk a work order from BOM to finished lot on your own item.
Agents for Manufacturing
BOM Variance
Flags jobs where the material actually used differs from the plan by 5% or more, up or down.
MakeProduction Schedule Optimizer
Orders work orders by shortest processing time, as a suggestion for a planner to adopt.
Material shortage
Checks a work order's components against stock on hand and shows the shortfall before the order is released.
Costing variance
Compares a work order's actual cost with plan and flags material overruns beyond the band you set (10 per cent by default).
Job-work reconciliation
Tracks material lying with each job worker and chases balances before the 180-day watch and the 365-day overdue mark.
Work-centre capacity watch
Says when to open the capacity board. A load that looks comfortable while orders are unrouted is reported as unreliable, not healthy.
Stock Forecaster
Forecasts demand for the next 30, 60 and 90 days for each item and warehouse, with a suggested safety stock and reorder point. It never acts on its own.
Buy3-way match
Matches the purchase order (PO), the goods receipt and the supplier's bill line by line, and holds the bill until any difference is sorted out.
Each agent is validated with each client before it touches their books, and every output waits for a person. Also in the setup: Reject-rate watch (items rejecting above your own limit, with coverage shown), a cycle-count prioritiser that picks which items to count first, and a maintenance-prediction agent.
Statutory and compliance calendar for a manufacturer (India)
Kinnow prepares; a person confirms and files. Dates are not printed because the department sets them; Comply carries your calendar.
| Obligation | What Kinnow prepares | Who confirms |
|---|---|---|
| ITC-04 (goods sent to and received from job workers) | A draft built from your job-work orders. It names what is stopping the export: a job worker's GSTIN or state, a missing challan number, an unknown unit, an overdue return. The due day and the return clock are confirmed by your CA | CA |
| Job-work e-Way bill | Raised from the job-work dispatch challan | Stores |
| GSTR-1, GSTR-3B and GSTR-2B | GSTR-1 built from your books and a file for portal upload; 2B reconciliation, which must be complete before a return is marked filed | Accounts executive, CA |
| E-invoice and e-Way bill on sales | Generated from the approved invoice and dispatch | Accounts executive |
| TDS and TCS challans and returns | Draft challans and return entries by section | CA |
| Payroll deductions | PF, ESI, professional tax and TDS on salary computed in the pay run | HR head |
What the owner sees
Ready-made questions from the setup, to type into Ask Kinnow. Each answer names its source report and what it will cost before it runs.
- Which work orders are behind schedule? Which work orders have no routing at all? (Work-order schedule)
- What is my BOM cost variance this month? Which runs are over their cost variance? (Production cost variance)
- Which materials are short for the next run? (Stock valuation)
- Which work centres are promised more than they can do?
- Show me every open production order. What did each line actually produce? (Work-order register, output by item)
- What failed inspection this month? What NCRs were raised? (QC inspection register, NCR register)
- Show dead stock older than 180 days. Where is purchase spend going? (Dead stock, purchase spend by category)
Illustration · sample data
| Work order · item | Material planned | Material issued | Variance |
|---|---|---|---|
| WO-0412 · Pulley housing | 120.0 kg | 128.5 kg | +7.1% |
| WO-0415 · Gear blank | 64.0 kg | 65.0 kg | +1.6% |
| WO-0419 · Shaft sleeve | 48.0 kg | 47.5 kg | -1.0% |
Numbers that matter
| Number | Report | What it tells you |
|---|---|---|
| Material and cost variance by run | Production cost variance | Which runs overspent and on what |
| Output by item and line | Output by item | What each line actually produced |
| Inspection failures and NCRs | QC inspection and NCR registers | Where quality is leaking, and from which supplier |
| Load per work centre, above 100 per cent shown as it is | Work-order schedule, capacity board | Whether the shop is over-promised |
| Dead stock value and purchase spend | Dead stock, purchase spend by category | Capital sitting idle and where buying goes |
See load per work centre on your own routings.
Applications switched on
| Generic term | In your Kinnow |
|---|---|
| production order | work order |
| work in progress | WIP |
| subcontracting | job work |
| quality failure | NCR (non-conformance report) |
| job-work return | ITC-04 |
Questions
Does Kinnow run MRP?
Yes, as advisory MRP. It works through multi-level BOMs against stock and open orders and proposes what to make and buy. It never creates a purchase order or work order by itself. The Production Planner turns the make recommendations into suggested work orders, and a person releases them.
Does it schedule the shop automatically?
No. There is a capacity board that shows the load on each work centre, and it can show more than 100 per cent, because that is the fact a planner needs. The Production Schedule Optimizer suggests a sequence of work orders, shortest processing time first, for the planner to accept or change. Automatic or constraint-based scheduling is not built.
Can it handle job work?
Yes. Job-work dispatch and receipt are tracked per challan; the job-work e-Way bill is raised from the dispatch; a reconciliation agent checks that sent equals consumed plus scrapped plus returned plus still out. The ITC-04 data is prepared as a draft for your CA to review and export. Kinnow does not file it.
What stops a BOM from referring to itself?
A BOM that would loop back on itself, or run deeper than 10 levels, is refused when you save it. A separate check-a-BOM screen is not offered; the check happens at save.
Is there a shop-floor screen?
Yes. A terminal lets an operator start and complete an operation. The time is taken from the clock, not typed, and an out-of-sequence or double start is refused with the step that is blocking. It runs in the browser; there is no offline mode or native app.
How do rejects reach the supplier?
An inbound inspection is created when goods are accepted above your limit. A failed lot raises a non-conformance report with severity and disposition (rework, scrap, use as is, return to vendor), and the supplier's pass rate is rolled up on a scorecard that purchasing sees when choosing a vendor.
How long to set up?
About two weeks to first results for one company: masters, BOMs and opening stock in week one, agents and a first close in week two.
Show me Kinnow for manufacturing.
Answer three questions. Get the applications, the agents and a two-week plan for your business.