Manufacturing Features

Manufacturing Orders

Create, track, and complete manufacturing orders for assembled or manually produced items from a single screen. ZavERP Manufacturing keeps bill of materials, quantities, deadlines, and statuses in sync so planners, operators, and warehouse staff always see the same version of reality.

Work Orders

Break each manufacturing order down into clear work orders assigned to specific workcenters or teams. Operators see exactly what to do, in what sequence, and with which materials, which keeps the shop floor organized even when priorities change during the day.

Barcode Operations

Use barcodes to move faster on the shop floor: start or pause a work order, record produced quantities, scan lots or serial numbers, and move items between locations. Barcode flows reduce typing errors and let operators focus on production instead of paperwork.

Repair Orders

Handle product repairs as a structured process, whether they are under warranty or provided as a paid service. Each repair order keeps track of used parts, labor time, and replaced components so you always know the real cost and history of every intervention.

Editable Manufacturing Orders

Adjust manufacturing orders on the fly when reality does not match the original plan. Consume alternative components, update quantities, or correct times even after work has started, while keeping a clean audit trail of what actually happened.

Disassembly & Component Recovery

Disassemble finished products to recover components for reuse, quality investigation, or scrap. ZavERP posts the right stock and cost movements automatically so inventory and costing remain accurate when you break down items.

Production Planning Overview

Get a visual overview of all manufacturing orders in a single planning board. Drag and drop to reschedule, change priorities, or shift work between days and workcenters so your plan stays realistic and aligned with actual capacity.

Organize Work Orders

Plan work orders by team, machine, or workcenter, and see available capacity at a glance. ZavERP helps you balance workloads, avoid bottlenecks, and ensure that downstream operations only start when upstream steps are ready.

Bill of Materials Availability

Check material availability directly from your planning views and manufacturing orders. The system shows which components are in stock, which need to be purchased or produced, and how this impacts lead times for confirmed orders.

Workcenter Capacity & MRP Scheduler

Use the built-in MRP scheduler to dispatch work based on capacity, calendars, and efficiency of each workcenter. The scheduler takes into account load, OEE, and constraints, helping you decide what to run, where, and when.

Multi-level Bills of Materials

Build multi-level bills of materials for complex products where subassemblies are produced separately. ZavERP handles nested BoMs, so changes in a component ripple through to finished goods without duplicated data or manual recalculation.

Optional Routing

Define simple BoMs without routings for straightforward products, or add detailed routings when you need step-by-step work orders. You can maintain multiple routings for the same product to support different production scenarios or plants.

Product Variants and Versions

Let products evolve over time with versions and configurable options. You can introduce engineering changes, new variants, or alternative components while keeping older versions traceable for service, spare parts, and compliance.

Kits and Sets

Sell and deliver kits as a set of components while still tracking each part in inventory. Sales sees one product on the order, while the warehouse ships the corresponding items, making it easy to manage bundles, starter packs, or assembly-at-customer kits.

Versioning of Products and BoMs

Track versions of products and bills of materials with a clear history of who changed what and when. Differences between versions are easy to review, which simplifies approvals and audits.

Engineering Change Orders

Use Engineering Change Orders (ECOs) to propose, review, and approve product or BoM changes. A visual kanban flow helps engineering and operations collaborate so that modifications are controlled and properly communicated to the shop floor.

Centralized PLM Data

Store all PLM information — BoM versions, ECOs, and related documents — in one place. You can group and merge changes that affect the same product structure, reducing duplication and keeping your product definition consistent.

Document Management on BoMs and Routings

Attach drawings, work instructions, and specifications directly to bills of materials and routings. Operators see the latest documents automatically on their work orders, which reduces outdated prints and miscommunication.

Quality Control Points

Define quality control points that automatically trigger checks at specific steps in the manufacturing process. You can enforce inspections on work orders, operations, or products so that critical controls never get skipped.

Quality Checks

Run quality checks with structured forms that can capture measurements, pass/fail decisions, pictures, or notes. Statistical and sampling rules can be applied to standardize how often and how deeply you inspect.

Quality Alerts

Create quality alerts whenever issues are found and manage them in a visual kanban board. Assign them to responsible users, track root-cause analysis, and document corrective actions so that problems are not only fixed, but also prevented in the future.

Preventive Maintenance

Schedule preventive maintenance based on machine usage, time intervals, or key performance indicators. ZavERP automatically creates maintenance requests before equipment fails, helping you avoid costly unplanned downtime.

Corrective Maintenance

Log corrective maintenance requests directly from the workcenter panel as soon as operators notice a problem. Maintenance teams receive all the context they need — machine, order, and issue description — to react quickly and efficiently.

Maintenance Calendar

Plan maintenance work in a calendar view, combining preventive and corrective tasks. This makes it easy to coordinate with production so interventions happen at the right moment with minimal impact on throughput.

Maintenance KPIs and Statistics

Follow maintenance KPIs such as mean time between failures (MTBF) and mean time to repair (MTTR). Historical statistics help you identify unreliable equipment, justify investments, and measure the impact of your maintenance strategy.

Tablets on the Shop Floor

Install tablets or terminals at each workcenter so operators can see their work orders in real time. The interface is optimized for touch screens and short interactions, making it practical even in demanding environments.

Record Production in Real Time

Let operators record produced quantities, scrap, and time spent directly from the workcenter panel. They can scan products, lots, and serial numbers so traceability and inventory stay accurate without extra paperwork.

Digital Worksheets

Display digital worksheets, drawings, and instructions right on the workcenter screen. Operators always follow the latest process, and changes are deployed instantly without printing and distributing updated documents.

In-line Actions and Exceptions

From the workcenter panel, operators can scrap products, raise quality alerts, request maintenance, or perform extra checks. Everything is logged against the right order and machine, giving you full visibility on what happened during production.

Guided Work Order Steps

Break work orders into clear steps linked to worksheet pages or actions. You can require specific actions such as scanning a product, capturing a photo, or confirming a quality result before operators can move to the next step.

Full Traceability

Get complete upstream and downstream traceability of components and finished goods. You can track which lots and serial numbers were used in each manufacturing order and where finished products ended up, which is critical for recalls and compliance.

Manufacturing Cost Analysis

Analyze the real cost of each manufacturing order by combining component consumption, labor time, and overheads. Compare standard and actual costs to see where margins are lost and which products or processes need attention.

Overall Equipment Effectiveness

Monitor workcenter performance with Overall Equipment Effectiveness (OEE) metrics and load analysis. Visual reports highlight productivity losses, bottlenecks, and underused resources so you can continuously improve your production line.