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Electrical and electronics

Manufacturing software for control panel builders

Know what a 7.5 HP DOL starter panel costs to build at today's contactor and copper prices, and let every batch take its parts out of the store when it is finished.

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In short

SimpleERP is manufacturing software for control panel builders in India. Each starter panel rating gets a bill of materials with enclosure, contactor, relay, MCB, wire and labour, and a work order consumes the parts and adds finished panels at actual cost.

Illustration of a bill of materials with cost roll-up and a work order moving from planned to in progress to completed.

A manufacturing day at Kovai Pump Controls

At Kovai Pump Controls a batch is ten panels of one rating. The wiremen mount the contactor, overload relay and MCB on the plate, run the copper wire, fit the meters, and the testing engineer powers each panel before it is boxed.

Contactor prices from the distributor move twice a year and copper moves every month. The owner's dealer price for a DOL starter was set two years ago, and he had no quick way to see whether it still left a margin.

What does a 7.5 HP DOL starter panel cost to build?

The BOM below is for a batch of ten. SimpleERP prices each line at the component's current average cost, adds 3% scrap on wire for offcuts and the labour and testing per batch, and shows the cost per panel as you type.

  • One BOM per rating: 5 HP, 7.5 HP and 10 HP each have their own.
  • A new version when you switch contactor brands; earlier work orders keep their recipe.
  • Estimated costs are flagged for a part not yet received, so the cost is not understated.
ComponentPlanned quantityAverage costCost
CRCA enclosure, powder-coated10 Nos₹780₹7,800
Contactor 25 A10 Nos₹1,150₹11,500
Overload relay10 Nos₹890₹8,900
MCB 3 pole 32 A10 Nos₹560₹5,600
Voltmeter and ammeter set10 sets₹420₹4,200
Copper wire 2.5 sq mm (3% scrap)30.9 m₹22₹679.80
Labour and testingper batch₹3,500
Total for 10 panels₹42,179.80
Cost per panel₹4,217.98
BOM v3 for ten DOL starter panels, 7.5 HP.

How does a batch of panels move through the floor?

Plan the work order and SimpleERP checks the component store for every part. Start it when the wiremen begin, and complete it after testing with the parts really used. Components leave the store and ten panels arrive in the finished store in one step.

  • Shortages flagged at plan time, with a button to raise a purchase order.
  • Start and complete from a phone at the test bench.
  • A one-page job card lists the parts to issue for the batch.

Illustration of a bill of materials with cost roll-up and a work order moving from planned to in progress to completed.

A work order for ten DOL starter panels, planned and short of nothing.

Can a dealer's order start the batch?

Yes. Pick the dealer's confirmed sales order on the work order and it plans only what is not already in the finished store. When the panels are done, invoice the order as usual.

  • The work order list shows which dealer each batch is for.
  • A panel that fails testing and uses a second contactor is entered as actual consumption, so its cost is right.

One system

What it connects to

A completed work order moves components out and panels in, and writes the journal with labour as overhead absorbed.

Honest limits

What SimpleERP does not do yet

  • No production stages or shop-floor tracking; a work order is planned, started and completed
  • No piece-rate pay or scrap by-product in the work order
  • Work orders are internal; job work sent outside is a purchase, not a work order
  • No test certificate or test record per panel; keep the test sheet outside SimpleERP

Getting started

Start with manufacturing

  1. Sign up with your phone

    Name, phone number and a password. No card for the seven-day trial, and email is optional.

  2. Tell us about the business

    Type your GSTIN and the state fills itself. Accounts, GST rates, units, roles and numbering are seeded for you.

  3. Add bills of materials

    Build the BOM for your most-sold starter rating first, with enclosure, contactor, relay, MCB, meters, wire in metres and a labour figure per batch.

  4. Complete a work order

    Components leave stock, finished goods arrive at real cost, and the journal posts in the same step.

FAQ

Questions, answered

Our enclosures are made by a vendor from our sheets. Can that be a work order?

No. Work orders are for what you make in-house. Material sent to the vendor moves by stock transfer to a warehouse named for that vendor, and the finished enclosures arrive on the vendor's purchase bill, ready to be a component in your panel BOM.

Can I make a mounting plate sub-assembly first and then the full panel?

Yes, one level at a time. Complete a work order for the wired plate, then use the plate as a component in the panel's BOM. Each step costs what it consumed.

One batch used more wire than the BOM says. Does it matter?

Enter the metres actually used when you complete. The extra leaves stock and the panels enter at a slightly higher cost, so the next price you quote a dealer starts from the real number.

Can the BOM tell me the cost of a 10 HP panel before I have bought the bigger contactor?

Yes. A component never received is priced at its purchase price and flagged as an estimate. Once the first distributor bill comes in, the BOM uses the real average cost.

Related

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