Bills of material that reflect the real process
A BOM in Busy can be multi-level, so sub-assemblies are defined once and reused, and it can carry wastage percentages, alternate materials and process-wise breakup. That matters because a BOM built on theoretical quantities produces a cost nobody trusts.
We build BOMs with your production head rather than from a drawing: standard input quantity, expected process loss, the substitutions actually used when a grade is unavailable, and the labour or overhead loading applied at each stage.
Once BOMs are in place, a production voucher consumes inputs and creates output in one entry, with variance against standard visible immediately.
- Multi-level BOM with sub-assemblies
- Wastage and process-loss percentages built into the standard
- Alternate and substitute material handling
- Standard versus actual consumption variance
- Unassemble voucher for dismantling and rework
Production, WIP and scrap
Production vouchers move material from raw to work-in-progress to finished goods, with WIP held in its own godown so the balance sheet reflects what is genuinely on the floor.
Scrap and by-products are captured as outputs with their own valuation, which changes product cost materially in trades like fabrication, plastics and foundry work where recovered scrap is real money.
Rejections and rework are recorded rather than absorbed silently, so a quality problem shows up as a cost line instead of a mysterious margin drop.
Job work, in and out
Job work is where most manufacturing setups fail, because the material leaves your premises but stays your stock and your GST liability. Busy handles both directions: material sent out on a job-work challan under GST, and material received in for processing when you are the job worker.
The system keeps a challan-wise register of what went out, what came back as finished or semi-finished goods, what came back as scrap, and what is still lying with the processor beyond the permitted period.
Job-work charges are booked against the challan so the conversion cost lands in the right product cost rather than in a general expense head.
- Job-work challan out and in with GST-compliant documentation
- Pending job-work register with ageing by processor
- Material reconciliation including process loss and scrap return
- Job-work charge booking into product cost
- Support for both principal and job worker roles
Product costing you can quote from
Costing in Busy builds up from actual issues: material at landed cost, job-work and process charges from the challans, and labour or overhead applied by your chosen basis. The result is a per-unit cost per batch, not an annual average.
Because the cost is batch-wise, you can see the effect of a raw-material price change or a bad production run on the specific lot it affected, which is what makes the number credible when you are quoting.
Comparing standard cost against actual over a quarter usually reveals one or two processes where loss is consistently higher than assumed. That single finding pays for the implementation in most units we work with.
Purchase, stores and consumption control
On the input side we configure purchase orders against reorder levels and production plans, goods-receipt with quality acceptance and rejection, and store issues against production orders or departments so consumption is attributable.
Landed cost brings freight, transport, insurance and clearing into material cost, which for imported inputs is the difference between a cost figure that means something and one that does not.
Multi-godown separation of raw material stores, WIP, finished goods, rejected material and scrap keeps the valuation clean and the physical counts manageable.
- Purchase order against shortage and production requirement
- Goods receipt with acceptance, rejection and return to supplier
- Store issue against production order or department
- Landed cost apportionment including imports
- Separate godowns for stores, WIP, finished goods, rejection and scrap
GST and statutory compliance for manufacturers
E-invoice and e-way bill generate from the invoice and delivery documents, including job-work challans which need e-way bills above the threshold. Input tax credit on capital goods and inputs is tracked, and reverse charge cases are configured explicitly.
GSTR-1, GSTR-3B and 2A/2B reconciliation run from the same books, and we test each transaction type you actually use — domestic sale, export, deemed export, job work, branch transfer — during implementation.
Where TDS or TCS applies to your purchases and sales, the rates and thresholds are configured so deduction happens at entry rather than at return time.
Reports a factory owner uses
Manufacturing reporting is about the relationship between output and input. Busy gives production versus consumption, yield by product and process, batch-wise cost, machine or line-wise output where you track it, and finished goods ageing.
Combined with the normal financials — profitability, cash flow, receivables and payables — this is enough for weekly review meetings without exporting anything to Excel.
- Production versus consumption and yield analysis
- Batch-wise and product-wise cost with variance
- Pending job work by processor and age
- Raw material shortage against production plan
- Finished goods ageing and stock valuation for bank statements
How we implement in a manufacturing unit
Manufacturing implementations are phased. Phase one is accounting, purchase, sales, stores and GST, which stabilises the books. Phase two is BOM, production and job work, which is where the costing value sits and which needs shop-floor cooperation to get right.
We spend time on the floor with your production and stores staff during phase two, because the vouchers only stay accurate if the people raising them understand why. Training is role-based, in Marathi, Hindi or English, and support afterwards is by phone, remote session and on-site visits around Pune and Maharashtra.
Manufacturing scenarios and how Busy handles them| Scenario | Busy handling | Reported as |
|---|
| Assembly from sub-assemblies | Multi-level BOM and production voucher | Batch-wise product cost |
| Material sent for plating or machining | Job-work challan out with register | Pending job work with ageing |
| Process loss and scrap recovery | Wastage in BOM, scrap as output | Yield and scrap value |
| Imported raw material | Landed cost apportionment | True material cost per unit |
| Rejection and rework | Rejection godown and unassemble voucher | Cost of quality |
