● Next-Gen Manufacturing ERP | TruSync × ERPNext v15
Precision in Production.
From Bill of Materials to Finished Goods—Gain complete visibility and control over your entire manufacturing process with TruSync and ERPNext.
SYSTEM STATE
● Online v15.0
OEE METRIC
Efficiency 98.5%
WAREHOUSE
Stock Optimal
SHOP SYNC
0ms Latency
AUDIT TRAIL
100% Traceable
Eliminate Factory Blind Spots
Manufacturing is chaos management. Stop juggling disconnected spreadsheets and start orchestrating your shop floor with a centralized brain.
⚠ Legacy Friction • Status Quo
The Challenge
When production planning happens in disconnected silos, operations grind to a halt over missing parts, delayed shift handoffs, and phantom margins.
✕ Disconnected data silos between Inventory and General Ledger Accounting
✕ Unpredictable machine downtime without automated maintenance triggers
✕ Material shortages halting high-value assembly lines mid-shift
✕ Inaccurate costing and blind margin erosion from untracked scrap
✔ TruSync Synchronized • ERPNext Core
The ERPNext Solution
A single authoritative platform where an inventory receipt automatically rebalances WIP allocations, triggers production orders, and syncs unit costs instantly.
✔ Real-time perpetual inventory sync with auto-generated GL accounting entries
✔ Closed-loop MRP schedules work orders dynamically based on confirmed sales
✔ Automatic multi-warehouse stock reservation for zero production halts
✔ Full landed cost calculations including operational machine and labor rates
100%
Component Traceability
0ms
Data Reconciliation Lag
Defining the Product: Multi-Level BOM
Handle complex product structures, sub-assemblies, and scrap management with ease. Every sub-component inherits revisions, routing, and live supplier costs.
ACTIVE MASTER BOM
Quantum Drone (Model QF-3)
Est. Unit Cost
$485.00
◆ Propeller Assembly
PA-001 • Sub-assembly (4 Units) • Sub-assembly
◆ Brushless Motor
RM-MT-220 • Raw Material • Raw Material
◆ Carbon Fiber Frame
RM-FR-CF4 • Raw Material • Raw Material
◆ 4S LiPo Battery Pack
RM-BT-4S • Serialized Batch • Raw Material
◆ Flight Controller MCU
EL-FC-X1 • SMT Electronics • Electronic
◆ Camera Gimbal Stabilizer
SA-CG-3X • Sub-assembly • Sub-assembly
Data-Driven Manufacturing Precision
TruSync configures ERPNext BOMs so that any change in material costs or scrap factors instantly updates projected margins across all open sales orders.
Automated Scrap Rates
Define normal vs abnormal scrap tolerances per operation so variances are absorbed into work-in-progress without manual ledger adjustments.
Versioned Change Logs
Maintain full revision control (Rev A, B, C) with engineering change orders (ECO), ensuring old revisions cannot be dispatched to shop floor stations.
Stock Availability Check
Instantly verify multi-warehouse inventory before launching work orders; auto-generate Purchase Requests for shortfalls.
Item Variant Routing
Support configurable manufacturing where attributes like color, voltage, and memory share a parametric parent BOM.
ERPNext CAD & PLM Bridge
Import BOMs directly from SolidWorks, AutoCAD, or Altium via REST API.
Strategic Planning & Closed-Loop MRP
From customer confirmation to purchase orders in seconds. Prevent stockouts, eliminate excess capital lockup, and align procurement directly with production schedules.
01
Sales Order Trigger
A sales rep or e-commerce channel logs a confirmed order for 50 Drones. The system validates credit lines and confirms delivery target dates.
Order #SO-9924 • 50 Units
Delivery Window: 14 Business Days
02
MRP Engine Calculation
The MRP engine explodes the multi-level BOM, audits current bin counts across 4 warehouses, discounts safety stock, and identifies net shortages.
Shortage Analysis • 42 Motors / 18 MCUs
Lead-time offset calculated automatically
03
Automated Production Plan
Generates Work Orders for sub-assemblies, auto-creates Material Requests (Purchase Orders) for vendors, and reserves physical warehouse components.
Work Order #WO-0881 • Dispatched
Purchase Order PO-7712 sent to supplier
● Real-Time Floor Telemetry
Shop Floor Real-Time View & Execution
Live monitoring of workstations, job cards, and human-machine operations. Every millisecond on the shop floor feeds into executive dashboards.
STATION ALPHA
CNC Station 01 • RUNNING
Machine Load 85%
OEE Efficiency 92.4% • Cycle Time 52s
LINE BRAVO
Assembly Line 3 • ACTIVE (4G/2Y)
Workstation Load 74%
Line Efficiency 88.0% • Throughput 194 / 210
QUALITY BAY
Final Testing Bay • RUNNING
Capacity Utilization 45%
Inspection Yield 98.0% • Mean Test Time 3m 15s
▤
The Work Order
The central conductor of factory operations. Signals the warehouse to release materials and instructs workstations to initiate operations.
Automated Stock Reservation
Locks designated lot/batch inventory against work orders so other sales lines cannot rob floor materials.
Instant Back-Flushing
Upon job completion, consumes raw materials dynamically based on verified production volume.
▣
Job Cards & Real-Time Tracking
Touchscreen shop-floor interfaces allowing machinists and assembly operators to clock in/out of specific operations like Precision Milling.
Planned vs Actual Variance
Pinpoints training gaps or equipment sluggishness by comparing standard cycle time against real operator timestamps.
Direct Operational Costing
Pushes real operator wage rates directly into finished goods inventory valuation.
✔
Integrated Quality Inspection
Gatekeeping checkpoints that prevent non-conforming items from reaching the next station or leaving the facility dock.
Standardized Acceptance Criteria
Define parameter bounds (e.g., Variance < 0.5%, Tensile > 400MPa) with pass/fail gates.
Auto-Quarantine Non-Conformance
Failed batches are automatically locked into quarantine warehouses pending MRB review.
Extended Traceability & Supply Chain
From aerospace grade serial tracking to external paint subcontractors, ensure every rupee and gram of material is fully accounted for.
▣
Serial & Batch Management
Full lifecycle tracking from raw supplier lot to warranty claims. Know exactly which batch of cells went into which drone chassis.
✔ Individual serial history & warranty activation
✔ Automated expiration date block on chemicals & adhesives
✔ Immediate recall genealogy reports in seconds
Traceability Standard • AS9100 / ISO 13485 Ready
▶
Subcontracting & Outsource Ops
Seamlessly manage outside operations (anodizing, powder coating, plating) without losing inventory control or costing accuracy.
✔ Subcontracting PO with linked stock delivery notes
✔ Vendor warehouse tracking of customer-supplied raw parts
✔ Auto-reconciliation of returned goods and scrap allowance
Service Cost Integration • Auto-Added to Landed Cost
▤
Perpetual Inventory & Financials
Every single stock movement creates a corresponding General Ledger entry in real time. Eliminate tedious month-end stock reconciliations.
✔ Full landed cost: Materials + Freight + Customs + Labor + Power
✔ FIFO and Moving Average valuation methods supported natively
✔ Granular WIP asset account balancing per work center
GL Reconciliation Lag • 0ms Real-Time
Data-Driven Decision Making & Unified Ecosystem
Turn raw sensor clicks and job cards into board-ready strategic intelligence. Manufacturing doesn't operate in a vacuum—ERPNext ties shop operations directly into HR, Maintenance, and Support.
Production & Volume Delay Analytics
Visualize throughput trends by shift, factory wing, and machinery category. Predict bottlenecks before they impact deliveries.
Asset Maintenance & Depreciation
Schedule preventive spindle overhauls based on actual CNC machine run hours from shop telemetry, avoiding costly downtime.
HRMS Payroll & Helpdesk Synergy
Employee Job Card timesheets sync to the HRMS module for incentive pay, while serialized items link to warranty tickets in Helpdesk.
ENTERPRISE BENCHMARK
TruSync Factory Impact • 2024 Audit Data
32%
WIP Reduction
Through automated Kanban pull and JIT staging.
99.2%
On-Time Dispatches
Closed-loop scheduling eliminates late parts.
4.2x
Faster BOM Revisions
Automated ECO workflow across shop stations.
Zero
Stockout Halts
Continuous MRP auto-reorder levels.
✔ Validated on 120+ Frappe / ERPNext plant deployments • Global Scale
▣ Modern Factory Operating System
Ready to Streamline Your Shop Floor?
Join leading discrete and process manufacturers who trust TruSync and ERPNext for total shop visibility, zero downtime, and closed-loop production orchestration.
✔ Official Frappe Partner
✔ ISO 27001 Certified
✔ SOC 2 Type II Compliant
✔ 99.99% Cloud SLA