From multi-level BOM and work order planning to shop floor WIP tracking, job work management, rejection recording, and actual cost per unit — manage the complete manufacturing operation from sales order to finished goods dispatch in one connected system.
From sales order through BOM-driven production planning, shop floor WIP, job work, costing, and receivables — every stage in one system, no data re-entry.
Every work order linked to its source sales order. Delivery commitment visible on the shop floor schedule. Status updates flow back to sales without manual follow-up.
Multi-level BOM exploded automatically at work order release. Material requirements calculated across all components and sub-assemblies. Shortages flagged before production starts.
Work-in-progress tracked at every routing step. Stage, percentage complete, and WIP value visible for each open work order without a physical walk or manual report compilation.
Actual cost accumulated per work order from real consumption. Customer outstanding and overdue invoices tracked alongside production. Margin by sales order from actual cost data.
Manufacturers operate on BOM-linked work orders, stage-wise WIP, job work reconciliation, production scheduling linked to sales orders, and actual cost per unit from real consumption. A generic ERP treats production as a simple stock movement — none of the actual factory workflow is supported without significant manual workarounds.
Bill of materials maintained in spreadsheets or product spec documents alongside the ERP. When a work order is raised, the materials required are worked out manually each time. There is no system link between the product structure and the shop floor order — so any BOM change is almost never reflected in live production.
Material issued to the shop floor disappears from inventory until finished goods are received back into the warehouse. What stage is a work order currently at? How much material is sitting mid-process? Nobody can answer without physically walking the shop floor or calling the production supervisor.
Material sent to job workers is tracked in gate registers or a standalone spreadsheet. Return quantities, in-process rejections at the job worker’s site, and outstanding material across 10 or 20 job workers are never reconciled in real time. Disputes arrive weeks after the event when the numbers are impossible to verify.
Production planning happens in Excel or in daily planning meetings. When a customer calls asking about their delivery date, the sales team checks with the plant, the plant checks their board, and the answer is an estimate. When priorities change, there is no system to show which work orders are affected.
Rejections at each production stage are noted by operators in shift reports but never entered into the ERP. Monthly yield per product or process is unknown. When production output and raw material consumption do not reconcile at month-end, the investigation is a manual review of shift registers going back weeks.
Standard cost is set in the system once a year. Actual material consumption per work order, actual process time, and overhead allocation are never rolled up into a real cost per finished unit. Margins are reported against standard — actual profitability by product or customer order is always an estimate.
BOM-linked work orders, stage-wise WIP tracking, job work reconciliation, sales-linked production scheduling, rejection recording with yield impact, and actual cost per unit from real material and process consumption are not add-ons in exactllyERP.
They are how exactllyERP works for manufacturers.
Every product defined by a system BOM with all components and sub-assemblies. Every work order raised against the BOM — material requirement automatically derived. Routing defines the process steps each work order passes through.
Work orders created from sales orders or production plan. Scheduled with start and completion dates. Material availability checked before release. Status tracked from open through WIP to completed.
Material issued to the shop floor is tracked as WIP at every routing stage. Completions recorded by stage. The current location and status of every work order is visible in the system without a physical walk.
Material sent to job workers tracked from issue through processing to return. Outstanding material with each job worker visible at any time. Returns, rejections, and shortages reconciled against the original issue challan.
Rejections at each production stage recorded against the work order with reason and quantity. Rework batches linked to the original work order. Yield per product and stage available for quality review.
Cost per finished unit built from actual material consumed, process time at each routing stage, and overhead allocation — not from standard cost rates. Variance against standard visible per work order.
Every stage in the manufacturing lifecycle connected in one system. A sales order triggers the production plan. The production plan drives work order release with BOM-exploded material requirements. Material is issued to the shop floor, tracked as WIP through each routing stage, inspected, received as finished goods, and dispatched against the original sales order — with cost accumulated at every step.
No manual handoffs. No data re-entry between stages.
Every work order traces back to the sales order that created it. Delivery commitment is visible on the shop floor schedule and in dispatch planning.
Material requirement for each work order exploded from BOM automatically. Shortages identified before work order release, not after production has started.
Material issued to production is tracked as WIP at each routing stage. The stage and percentage complete for every live work order is visible without a physical count.
Rejections recorded per routing step with quantity and reason. Rework order linked to original. Yield by product and stage available from the system.
Job work operations are part of the routing. Material issued to the job worker is tracked as stock at the external location. Return closes the challan and updates the work order.
Cost is accumulated at every stage — material issue, process time, job work charges, overhead. Actual cost per unit is available at work order close.
Multi-level BOM, work order management, WIP tracking, job work reconciliation, rejection and rework, production scheduling, inventory across locations, purchase and supplier management, and actual costing — each built around how a real factory operates across engineering, fabrication, assembly, and process manufacturing.
Assemblies, sub-assemblies, and raw material components defined at any depth. BOM versioned with revision history. Material requirement exploded automatically when work order is raised.
Sales-order-linked production plan with material availability check. Work orders scheduled with start and end dates. Capacity view by work centre. Overdue work orders flagged automatically.
Work orders created from sales orders or plan. Status tracked through open, in-process, inspection, and completed. Material availability checked at release. Sales delivery commitment visible on schedule.
Stage-wise WIP tracked from material issue through each routing step to FG receipt. Work order location and percentage complete visible at all times. WIP value available without month-end estimation.
Job work challans issued and tracked. Material at each job worker visible as a separate location. Returns reconciled against issue. Overdue challans flagged. Job worker-wise outstanding for GST compliance.
In-process rejections recorded per routing step with reason and disposition. Rework order linked to original. Scrap inventory updated. Yield by product, stage, and work centre available for quality analysis.
RM, WIP, semi-finished, and FG inventory tracked across warehouse, shop floor, and job worker locations. Transfers recorded. Stock available at each location visible without a physical count.
Purchase orders raised against production-triggered MRP or manual requisitions. Supplier-wise GRN, quality inspection, and invoice matching. Outstanding POs and pending inward always visible.
Actual cost per unit from real material consumption, process time, and overhead. Standard vs actual variance per work order. Margin by product, customer, and sales order from actual cost data.
Delivery date queries, material shortages before production starts, job worker outstanding, WIP location questions, rework investigations, margin reviews — situations that come up every day on the shop floor. exactllyERP handles each without a manual search across registers and spreadsheets.
A customer calls asking when their order SO-2024-318 will be ready. Sales needs to tell them something accurate, not an estimate. The order has three products, each with a separate work order at a different stage.
Production planning wants to release Work Order WO-2024-419 for 150 units of Assembly X. Before issuing the shop floor order, they need to know if all materials are available so the job does not start and then stall mid-process.
Purchase team needs to review all open job work challans before the GST return is due. Which job workers have material that has been outstanding for more than 60 days without return?
QC manager notices that material consumption for Component Z this month is significantly higher than planned. She wants to know whether the overrun is from in-process rejection or from rework on any work orders.
Production manager needs to know how many work orders are currently in progress, what stage each one is at, and which ones are behind schedule — before the morning review meeting.
Management wants to know the actual profit margin on Sales Order SO-2024-312 for a key customer — using real material and production costs, not the standard cost estimate that was used for the quote.
Every metric a manufacturing management team needs — live from the system, no manual compilation required.
Work-in-progress value by product, stage, and work centre. Updated as each routing step completes — no month-end WIP estimation.
All open work orders with current stage, completion percentage, scheduled date, and days ahead or behind. Overdue work orders flagged automatically.
Components short against open work orders and production plan. Quantity required vs available, with pending PO delivery dates. Shortages that will stop production identified upfront.
Actual production output against planned quantities by product and period. On-time delivery rate against sales order commitment dates tracked from the system.
In-process rejection rate by product, routing stage, and work centre. Trend over time and cost impact of rejections. Rework volume and additional cost per period.
Material value at each job worker, challan age, and overdue position. GST reversal risk on challans beyond 180 days flagged. Job worker reconciliation status at a glance.
Actual vs standard cost per work order. Material over-consumption, process time deviation, and overhead variance identified at work order close. Variance trend by product.
Actual margin per sales order and customer from real production cost data. Gross margin by product family and period. Profitable vs unprofitable orders visible without month-end close.
From production planning and shop floor to quality, job work, finance, and management — every role gets what they need from the same connected system.
Create and release work orders from the production plan. BOM-driven material requirements auto-calculated. Shortages identified before release. Overdue work orders flagged on the schedule.
Record material issues to the shop floor. Update stage completions as work progresses. WIP position by routing step always current. Work order location visible without manual follow-up.
Record rejections at each routing stage with reason code. Initiate rework orders linked to original. Yield by product, stage, and period available from the system for quality review.
Issue job work challans and track material at each subcontractor. Reconcile returns against issue. Raise purchase orders against production-triggered shortages. GRN and quality inspection in the system.
Actual cost per work order from real consumption. Variance against standard identified at closure. Customer outstanding and overdue invoices tracked. Margin by sales order from actual cost data.
WIP position, work order status, rejection trends, job worker outstanding, actual cost variance, and margin by order — all from one system without waiting for manual reports.
Your ERP holds all the data — work order status at every stage, WIP by location, job worker outstanding, material availability against open orders, rejection and rework records, actual cost per work order. The AI Copilot lets you ask questions the way you would ask your production manager and get the answer immediately.
No report requests. No waiting. No dependency on someone pulling a query.
Generic ERP records purchase orders, production orders, and invoices. Manufacturers need multi-level BOM linked to work orders, stage-wise WIP tracking, job work reconciliation with outstanding visibility, rejection recording with yield impact, sales-linked production scheduling, and actual cost per unit from real consumption data.
None of these are handled natively by a standard system — without costly customisation.
Questions manufacturers ask about BOM management, shop floor tracking, job work, rejection handling, costing, and production-to-dispatch visibility — answered from how exactllyERP actually works.
Multi-level BOM is defined in exactllyERP with parent-child relationships, component quantities, and routing steps per operation. Material requirements are derived automatically from the work order — no separate MRP spreadsheet. Changes to the BOM propagate to all open work orders referencing it.
Each work order stage is updated as it completes. WIP quantity, stage, and time spent are visible in real time across all open work orders. Rejection and rework are captured at the stage where they occur — giving an accurate picture of what is genuinely in progress on the floor.
Yes. Job work challans are raised for material sent to subcontractors with quantity and expected return date. Material received back is reconciled against the challan. Job worker GST liability is tracked separately. Open challans and outstanding balances per job worker are available from the system at any time.
Rejection is recorded at the specific production stage with reason code. Rework is tracked as a separate work order or sub-stage. exactllyERP shows rejection rate by stage, by product, and by period — making it possible to identify where yield loss is occurring and quantify the cost impact.
exactllyERP accumulates material cost from actual issues, process cost from routing steps, and overhead allocations per work order. Actual cost per unit is compared against the standard cost defined in the BOM. The variance — and its source — is visible at work order closure.
Sales orders drive production demand in exactllyERP. Planned production quantities are derived from open sales orders and delivery dates. Work orders are released against the plan — and the sales order delivery status is updated automatically as work orders progress through production and goods are received into finished goods stock.
A walkthrough covering BOM and work order management, shop floor WIP tracking, job work reconciliation, rejection and rework, production scheduling, and actual cost per unit — built around how your factory actually operates.
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