Streamline Gauge and ToolManufacturing with ERPNext

ByVANTOS

Gauge and Tools Manufacturing ERP

Implementing manufacturing operations for Gauges and Tools, a thread plug gauge manufacturer, in ERPNext involves defining a workflow tailored to their processes. Below is a step-by-step guide to designing this in ERPNext

1. Setup Basic Manufacturing Structure

  1. Workstation Setup:
    • Create workstations for each operation in the manufacturing process.
    • Examples:
      • Lathe Machine
      • CNC Machine
      • Heat Treatment
      • Grinding
      • Quality Inspection

2. BOM (Bill of Materials):

    • Define BOMs for each type of thread plug gauge.
      • Include:
        • Raw materials: Steel rods, Carbide tips, etc.
        • Consumables: Coolants, Cutting fluids.
        • Operations: Listed in sequenc

2. Define Manufacturing Workflow Operations:

Operations:

  1. Raw Material Preparation:
    • Cutting steel rods to required sizes.
    • Operation: Cutting.
  2. Initial Machining:
    • Shaping the rod using lathe machines.
    • Operation: Lathe Machining.
  3. Precision CNC Machining:
    • Creating accurate threads using CNC machines.
    • Operation: CNC Threading.
  4. Heat Treatment:
    • Hardening and tempering for durability.
    • Operation: Heat Treatment.
  5. Grinding:
    • Ensuring dimensional accuracy and smooth surface finish.
    • Operation: Grinding.
  6. Assembly (if applicable):
    • Attaching carbide tips or other components.
    • Operation: Assembly.
  7. Final Quality Check:
    • Dimensional checks, thread pitch measurements, etc.
    • Operation: Quality Inspection.

3. Quality Control Workflow

  1. Add Quality Inspection Templates for:

    • Dimensional Accuracy
    • Surface Finish
    • Hardness Testing
    • Thread Tolerance (Plug or Ring Gauge standards)

  2. Configure ERPNext to ensure:

    • Quality Inspection is mandatory before proceeding to the next operation.

    • Rejection is logged with corrective action workflows.

4. Job Card and Production Plan

  1. Create Job Cards for each operation linked to:

    • The Work Order.
    • The respective Workstation.

  2. Develop a Production Plan to:

    • Schedule workstations and operations.
    • Optimize resource allocation.
    • Handle priorities and rush orders.

5. Material Movement and Costing

  1. Use Material Request to track raw material requirements.
    • Issue materials using Stock Entry (Material Transfer for Manufacture).
    • Log costs at each stage to track actual vs. planned costs:
      • Labor costs
      • Machine hour costs
      • Material costs

6. Reporting and Analytics

  1. Configure reports for:
    • Work Order Progress
    • Material Variance
    • Production Efficiency
    • Rework and Scrap Reports

Example ERPNext Workflow:

  1. Create Work Order: Based on customer order or production forecast.
  2. Generate Job Cards: Assign workstations and operators for each operation.
  3. Track Progress: Update job card status as tasks are completed.
  4. Perform Quality Checks: Approve or reject items after each critical operation.
  5. Complete Work Order: Once all tasks and quality checks are completed.

Manufacturing Process

Data Analysis

Raw Material Preparation

Initial Machining

Precision

Heat Treatment

Grinding

Quality Check

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Benefits

This workflow can be customized further based on specific business needs, additional quality checks, or regulatory compliance requirements.

End-to-End Traceability

Track materials from raw to finished goods.

Quality Assurance

Integrated quality checks ensure consistent product standards.

Process Automation

Streamline repetitive tasks like material requests and stock updates.

Cost Control

Accurate costing with BOMs and Work Orders.