Issues in ERPNext for Continuous Production (HDPE Pipe Extrusion)
Hello Community,
We are using ERPNext Manufacturing for continuous production (HDPE pipe extrusion). Our production runs continuously across shifts and days, and Job Cards are used mainly for shift-wise production tracking, not as discrete batch completion.
We are facing the following core challenges:
-
Planned vs Actual Quantity in Job Card Treated Incorrectly as Process Loss
Scenario:
Job Card planned quantity: 1000 meters
Actual production in the shift: 700 meters
Current Behavior:
ERPNext treats the remaining 300 meters as process loss / variance
Problem:
In continuous production, this is not a loss
It is simply pending production, which will be produced in the next shift or job card
No material is wasted, and the machine continues running
Expected Behavior:
Balance quantity should remain open / pending
It should not be classified as process loss or inefficiency
Job Card should support partial completion without loss accounting -
Stock Entry Not Allowed Against Partial Completion of Work Order
Scenario:
A Work Order is for a large quantity (e.g., 15,000 meters)
Production happens shift-wise via multiple Job Cards
Only part quantity is produced and ready for dispatch
Current Limitation:
ERPNext does not allow Finished Goods Stock Entry unless the Work Order is completed
Problem:
In real operations, we dispatch and invoice daily / shift-wise
Waiting for full Work Order completion is impractical in continuous processes
Expected Behavior:
Stock Entry for Finished Goods should be possible against partial completion
Produced quantity from Job Card should be allowed to move to FG stock
Work Order should remain open for remaining quantity -
Operating Cost Calculated on Time Instead of Output Quantity
Current Behavior:
Operating cost is calculated based on machine time / job card time
Problem:
In extrusion-based continuous manufacturing:
Output quantity (meters/kg) is what matters
Time alone does not represent actual production efficiency
Two shifts may run same hours but produce different output
Expected Behavior:
Operating cost should be calculated based on Finished Goods produced
e.g., cost per meter or cost per kg
Cost should scale with actual production quantity, not just time bookedLooking forward to insights from others who have implemented ERPNext in continuous or process manufacturing environments.
Thank you.
