ERP built around how a pump unit, foundry, mill or machine shop actually runs: bills of material, production, job work going out to platers and machinists, GST e-invoices and e-way bills, dealer orders and quality records. Built in phases by our team in Sulur, with SMS and WhatsApp alerts on our own gateway.
AvanceZone builds custom ERP software for manufacturing units in and around Coimbatore. We do not sell a packaged ERP. We study how material, jobs and money move through your unit, then build the modules you need: bills of material, production planning, job work in and out, inventory with batch or heat numbers, GST e-invoicing and e-way bills, dealer orders and quality records. Alerts go out by SMS and WhatsApp from our own platform. The system is rolled out in phases, priced after a requirement study, and the source code is yours.
Coimbatore has more than 25,000 small, medium and large industries and supplies nearly 50% of India's motors and pumps, according to Wikipedia's Coimbatore article. It also has several hundred foundries, going by a Bureau of Energy Efficiency cluster study and trade press counts. Most of these units keep accounts in Tally, which handles GST well. The gaps are on the shop floor.
The BOM lives in an Excel file one person understands. Castings sent for machining are written in a challan book. Nobody can say, without phoning around, how many impellers are at the plating vendor or whether a dealer's order can ship this week. At month-end someone reconciles it all into Tally by hand.
A custom ERP joins those records up. It does not have to replace Tally: a common setup keeps Tally for accounts and lets the ERP post vouchers into it.
An ERP for a pump assembler and one for a foundry share accounts and inventory, and little else. These are the records we design around for each.
Multi-level BOMs (pump set, motor, stator, winding), copper issued by weight against each winding job, a serial number per pump with its test-bench readings, and warranty claims traced back to the batch. Dealer orders and dispatch by model and rating.
Heat numbers carried from melting through fettling, machining and dispatch, so a rejected casting traces back to its heat. A register of customer-owned patterns, rejection by defect and by customer, and per-kg or per-piece billing.
Lot-wise cotton and yarn stock by count, job work for sizing, weaving or processing, and dispatch by lot. Roll-level fabric QC is better handled by our separate fabric inspection product than rebuilt inside the ERP.
Material received on the customer's challan and kept out of your own stock value, route cards per operation, machine and operator time, and return challans that close each lot. Suits units machining parts for larger manufacturers.
Few units need all of these on day one. We start with the modules that remove the most manual work and leave the rest for later phases.
Multi-level bills of material with revisions and alternate items, plus the sequence of operations. A BOM change shows which open orders and purchase plans it affects.
Work orders from sales orders or dealer demand, shortages shown before release, and a daily plan per machine or line, updated from the floor on a phone.
Challans for material sent to vendors, receipts against each challan, process loss and scrap, and a live view of stock at every vendor.
Stores by location; batch, heat or lot numbers where traceability matters; reorder levels; stock checks with variance reports.
IRN and QR code for B2B invoices from the Invoice Registration Portal, and e-way bills generated from the invoice through a GST Suvidha Provider or the government API.
A dealer login or WhatsApp ordering, price lists per dealer, order status, dispatch details and outstanding statements on request.
Incoming inspection, in-process checks, final test results and non-conformance reports, each linked to its batch or serial number.
Dispatch details and payment reminders to dealers; low-stock and overdue-challan alerts to the owner, on DLT-registered SMS and approved WhatsApp templates.
Today's dispatches, pending orders, material at vendors, rejections by cause and receivables by dealer, on one screen or on WhatsApp each morning.
Job work is where manual records most often break down, and it has GST consequences. When a principal manufacturer sends inputs to a job worker, they go under a delivery challan. Under Section 143 of the CGST Act, inputs have to come back within one year and capital goods within three years; if they do not, the original dispatch is treated as a supply. Moulds, dies, jigs, fixtures and tools are outside that time limit. The principal also files Form GST ITC-04, which reports goods sent to and received back from job workers.
The ERP keeps every challan with its items, quantities and weights, matches each receipt against it including process loss and scrap, and warns you before an open challan reaches its limit. ITC-04 data then comes from those records instead of the challan book.
We build custom ERP, and it is not always the right answer. This is the comparison we walk through in a requirement study.
| Option | Licence & cost model | Works well when | Watch out for |
|---|---|---|---|
| Tally with add-ons | TallyPrime licence plus TDL add-ons from a Tally partner | Accounts and GST are the centre, with basic BOM, manufacturing journals and job-work orders | Little shop-floor detail such as routings, heat numbers or inspection records; add-ons from different vendors may clash |
| ERPNext | Open source; free to self-host, or paid hosting and implementation | You want a full ERP with manufacturing, Indian GST support through community apps, and an implementation partner | Customisation is in Python on the Frappe framework; heavy changes make upgrades harder |
| Odoo | Free Community edition; Enterprise is a per-user subscription | You want a modular suite with manufacturing, inventory and many add-on apps | Cost grows with users; some features are Enterprise-only; you depend on a partner |
| SAP Business One | Per-user licence through an SAP partner | A mid-sized company with budget for licences and a structured implementation | Licence and implementation cost; changes go through the partner |
| Custom ERP (what we build) | No per-user licence; development priced per phase after a requirement study, plus optional support | Your process does not fit a template: heat traceability, customer patterns, model-wise BOMs, dealer rules, job work at volume | Slower to start than installing a product, so we phase it; insist on documentation and source code, which we hand over |
If Tally plus one good add-on covers most of what you need, that is the cheaper path and we will say so. A common middle path is to keep Tally for accounts and build only the production and job-work side.
ERP projects go wrong when everything switches on the same Monday. We release in phases, and each one is in daily use before the next begins.
Time on the floor, in stores and in accounts. We collect your challans, route cards and test reports, then write the scope, phases and a fixed price.
Item masters, stores, purchase, sales, GST invoices, e-invoice and e-way bill. Opening stock loaded and checked.
BOMs, work orders, job-work challans and receipts, and floor updates from phones.
Dealer ordering, quality records, SMS and WhatsApp alerts, and the owner's summary.
Old and new records kept side by side through at least one month-end, until the numbers agree.
Training in Tamil or English, then an annual support contract and changes as your process changes.
We do not claim an ERP product. What we have is business software built for specific clients since 1998, and vertical products we run ourselves.
Our GST billing and inventory case study is the closest example: a distributor moved off desktop billing on one back-office PC to a web system with GST invoicing, real-time stock, supplier and customer ledgers and GST reports, used from the counter, the godown and the owner's phone.
For textile units, our fabric inspection software handles roll-level QC: inspectors log defects by voice in Tamil or Hindi, the software applies the 4-point or 10-point system, and the buyer gets a report. It is a product, separate from any custom ERP.
Other systems we built, such as a timesheet and payroll system with approvals and payroll exports, are on our projects page.
There is no fixed ERP price on this page because there is no standard ERP. The price is fixed after the requirement study, in writing, phase by phase. These decide it:
Bring a challan, a route card and last month's dispatch register. We will tell you which records an ERP should take over first, and send a fixed price per phase.
