Stone crushers and M-sand
Manufacturing software for stone crushers
Turn boulders into a cost per tonne for M-sand and each aggregate size, with a bill of materials and a work order for every crushing run.
In short
SimpleERP is manufacturing software for stone crushers and M-sand units in India. A bill of materials plans boulders per tonne of output, a work order records each crushing run, and the product enters the yard 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 Godavari Blue Metal and M-Sand
On a good day the jaw crusher at Godavari Blue Metal and M-Sand takes about 600 tonnes of boulders. The cone and the screens split it into 40 mm, 20 mm, 12 mm and 6 mm, the VSI turns part of the flow into M-sand, and quarry dust is left at the end.
The partners price by habit, yet the cost of a tonne moves with the boulder source, the diesel for the excavator, the power bill and how hard the jaw plates are wearing. Without a record of each run, the M-sand rate quoted to a builder is a guess.
SimpleERP records crushing through work orders. A bill of materials says how many tonnes of boulders a tonne of output needs, a work order consumes what was really fed, and the output enters the yard at the run's actual cost.
How do I write a bill of materials for aggregate?
A BOM gives the boulders per batch of output, a scrap percentage for fines lost in the plant, and labour and power per batch. The table is a BOM for 100 tonnes of 20 mm, with boulders at their current average cost.
- One BOM per size you cost, such as 20 mm and M-sand.
- Power, diesel and labour per batch added to the output's cost.
- Standard cost per tonne shown as you type.
| BOM line | Per 100 t of 20 mm | Cost |
|---|---|---|
| Boulders | 100 t @ ₹420 | ₹42,000 |
| Scrap allowance | 3% | ₹1,260 |
| Power, diesel and labour per batch | per 100 t | ₹9,500 |
| Standard cost | ₹527.60 per tonne | ₹52,760 |
What is the yield from a day's boulders?
A typical day's 600 tonnes of boulders gives around 180 tonnes of 20 mm, 90 of 40 mm, 80 of 12 mm, 60 of 6 mm, 150 of M-sand and 30 of quarry dust, with about 10 lost as fines. One work order covers one output, so choose how to record the rest.
- The main size as the work order output, with its share of boulders consumed.
- Other sizes added by stock adjustment with the reason Other and the run in the note.
- Or a work order per size, each consuming the boulder share you allocate.
Illustration of stock on hand by warehouse at average cost, with a low-stock row highlighted and a movement ledger.
How does a crushing run move from plan to complete?
Plan the work order for the tonnes you expect, and the boulders needed are frozen with any shortage in the quarry yard flagged. Start it when the jaw crusher starts, and complete it with the tonnes measured off the stockpile and the boulders actually fed.
- Complete from the plant on a phone.
- Consumption defaults to the plan scaled to the output, editable line by line.
- Planned against actual boulder cost kept on every run.
Why does M-sand cost more some weeks?
Because each completed run carries its own consumption. When softer boulders or worn VSI tips mean more feed per tonne of sand, the higher boulder figure shows on that work order and lifts the M-sand average from that day on.
- Filter work orders by product, yard and date.
- Overhead absorbed posted with each run.
- Link a run to a sales order for a builder's booked quantity.
One system
Where manufacturing connects
A completed crushing work order takes boulders out of the quarry yard, puts the size in at actual cost and posts the journal at once.
Stone crushers and M-sand
Truckload invoices per aggregate size, builder credit with ageing, and depreciation on crushers.
See howGST billing for stone crushers
One GST invoice per tipper, every aggregate size with its HSN, and the builder's balance updated before the next load.
See howInventory for stone crushers
Boulders, every aggregate size, M-sand and store spares in tonnes, litres or pieces per yard, at weighted average cost.
See howAccounting for stone crushers
Builder dues, diesel, royalty, spares and machine depreciation in one ledger that writes itself from documents.
See howPayroll for stone crushers
Two-shift attendance for operators and drivers, PF and Maharashtra PT, and advances recovered from monthly pay.
See howManufacturing
Bills of materials with scrap and cost roll-up, and work orders from plan to complete.
See how
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 by-product yield split in a single work order: one size is the output, the rest go in by adjustment or their own work orders.
- No stage-wise counts from the jaw, cone or VSI.
Getting started
Start with manufacturing
Sign up with your phone
Name, phone number and a password. No card for the seven-day trial, and email is optional.
Tell us about the business
Type your GSTIN and the state fills itself. Accounts, GST rates, units, roles and numbering are seeded for you.
Add bills of materials
Add boulders as a component and a bill of materials for 20 mm and for M-sand, with boulders per batch, a scrap percentage and power and labour per batch.
Complete a work order
Components leave stock, finished goods arrive at real cost, and the journal posts in the same step.
FAQ
Questions, answered
Can one work order produce every size from the screens?
No. A work order has one output. Most crushers make their main size or M-sand the output and add the other sizes by stock adjustment with the run noted. If you need a cost for every size, run one work order per size with the boulders you allocate to it.
Our boulders come from our own quarry. What cost do they carry?
Whatever you put into them. Bought boulders take the supplier bill rate. Own-quarry boulders can enter stock by adjustment at a cost per tonne you work out from royalty, blasting and excavator expenses, and the work order then uses that average.
Can I record the cone crusher and VSI as separate stages?
No, there are no production stages. A run is planned, started and completed as one work order. If you sell 20 mm before it goes through the VSI, it is simply a product in stock, and an M-sand work order can consume it as a component.
Does SimpleERP count the tonnes coming off the conveyor?
No. There is no plant or weighbridge integration and no shop-floor counting. The operator or supervisor enters the tonnes produced when completing the work order, measured however you measure today: by trips, a pile survey or the belt scale reading.
Related
Keep reading
Stone crushers and M-sand
Truckload invoices per aggregate size, builder credit with ageing, and depreciation on crushers.
Read moreInventory for stone crushers
Boulders, every aggregate size, M-sand and store spares in tonnes, litres or pieces per yard, at weighted average cost.
Read moreAccounting for stone crushers
Builder dues, diesel, royalty, spares and machine depreciation in one ledger that writes itself from documents.
Read more
See how manufacturing works in SimpleERP for stone crushers and M-sand
Seven days free. No card. Your first GST invoice in minutes.