BOM-driven auto-PRs ensure raw materials arrive before production stalls. Clinker silos, coal heaps, gypsum bays, and additive stores — managed in real time with intelligent reorder logic.
A cement plant is a continuous process — if clinker or coal runs out, the entire operation shuts down. Every hour of unplanned stoppage costs lakhs in lost production and idling costs. The Procurement & Inventory module eliminates stock-outs through intelligent, BOM-linked reorder logic that triggers purchase actions before the crisis, not during it.
Clinker silos are tracked level-by-level in real time. Coal heaps are managed by stack, with FIFO consumption tracking ensuring older stock is used first. Fly ash, gypsum, and slag inventories update automatically when GRNs are posted. The Purchase Manager sees one clean dashboard showing what is low, what is ordered, and what is in transit — without opening a single spreadsheet.
Store Keepers discover low coal stock the evening before a production shutdown. Purchase Manager calls vendors on mobile. Emergency coal arrives at a 15% premium price. Clinker silo levels are maintained on a whiteboard that nobody updates. Raw material costs spiral because procurement happens reactively, not proactively.
Reorder points are configured per material. System monitors stock continuously and auto-generates Purchase Requisitions the moment levels hit the threshold — giving 5–7 days of buffer for the vendor to deliver. All procurement activity leaves a full audit trail for Finance and Management.
From automatic purchase trigger to physical goods receipt — the full procurement cycle without manual gaps.
Every raw material in the plant — clinker, coal, gypsum, fly ash, slag, packing bags, fuel oil — has a reorder point and minimum stock level configured in the material master. When actual stock falls to the reorder level, the system automatically generates a Purchase Requisition and routes it to the Purchase Manager for approval. The PR includes current stock, reorder quantity (calculated from production plan), preferred vendor, and last purchase price — everything the manager needs to approve in one screen.
The vendor master maintains a pre-approved supplier list per material with ratings, lead times, and price history. When an approved PR is converted to an RFQ, the system sends quotation requests to 3–5 preferred vendors automatically. Responses are entered into the comparative statement, which ranks vendors by price, lead time, and quality score. The Purchase Manager approves the selected vendor, and the PO is auto-generated — routed to Finance for budget approval above configurable thresholds.
When material arrives, the Store Keeper creates a Goods Receipt Note (GRN) against the open PO. The system verifies quantities, triggers quality inspection for applicable materials, and updates inventory. For clinker, each GRN updates the specific silo balance. Silo-wise stock is visible in real time on the plant dashboard. For bulk coal, the GRN updates the specific heap or yard location. Finance receives GRN confirmation for vendor invoice matching.
Coal inventory is managed by stack/heap with unique stack IDs. Each GRN assigns coal to a specific stack with receipt date, quantity, and quality (GCV, moisture, ash content). When Production issues coal, the system enforces FIFO — oldest stock is consumed first — preventing quality degradation from long storage. Stack-wise balances and heap map are visible to the Plant Head and Purchase Manager at all times.
Every feature built for the unique raw materials and inventory patterns of a cement plant.
Every department depends on Procurement to keep materials flowing — and Procurement depends on every department for accurate consumption signals.
PO approval above threshold requires Finance budget clearance. GRN triggers vendor invoice matching. TDS deduction computed on applicable vendor payments.
Finance ModuleMaterial consumption from Production triggers stock deductions. When stock falls to reorder level, auto-PR fires. Production never sees a shortage that wasn't anticipated.
Production ModulePredictive procurement uses consumption trend data to anticipate stock-outs 2–3 weeks in advance, adjusting reorder quantities based on production forecast and market supply signals.
AI Features