GP Plast: a plastics plant run on FLAPP ERP — production in front of management as it happens
From the sales order to the journal entry, the whole plant runs on one system. The production team records output, scrap and machine stoppages from the line, and the numbers turn straight into KPIs for every line and shift — while stock and accounts move with them, with nothing entered twice.
The system — A whole plastics plant on one system
From the sales order to the journal entry, GP Plast runs on FLAPP ERP. The sales order reaches production, production is recorded from the line, and stock and accounts move with it — while management sees all of it as live KPIs.
- → Sales — the sales order
- → Production — a job order on the line
- → The line — output, scrap and stoppages
- → Warehouse — raw material out, product in
- → Accounts — every movement has its entry
- → Management — live performance KPIs
The challenge — The numbers have to arrive while they still matter
The lines run in shifts, and every shift has its own output, scrap and stoppages. If those numbers are only collected at the end of the day, the problem has already happened — and there is no time left to fix it.
- ✕ Output known only after the shift
- ✕ Scrap counted at the end
- ✕ Why a machine stopped, forgotten
Tracking — Production is recorded on the line
The production team records it from the line, as it happens — not afterwards: output, scrap, and machine stoppages with their reasons — and every record is tied to its job order.
- ✓ Output for every line, every shift
- ✓ Scrap recorded with production
- ✓ Every stoppage with its reason and duration
- ✓ Each job order knows how much is left
The KPIs — Performance on a live dashboard
Everything recorded turns straight into performance indicators for management — for every line and every shift.
- ✓ Output and scrap rate
- ✓ Downtime and its reasons
- ✓ Lines and shifts side by side
- ✓ An underperforming line shows up early
Inventory — Production moves the warehouse on its own
Every production record issues the raw material it used from the warehouse and puts the product into its own warehouse. So the balance management sees is what is actually on the floor — and when an order is complete, it moves on to delivery.
- ✓ Raw material issued with production
- ✓ Product received into stock automatically
- ✓ Every warehouse balance, live
- ✓ Completed orders move on to delivery
Accounting — Sales and production reach the books on their own
Accounting is linked to sales and production: an invoice is booked to the customer's account, receipts and payments are vouchers that are reviewed and approved before they post, and maintenance costs reach expenses on their own. The income statement and trial balance come from the same numbers as the line.
- → Invoice — to the customer's account
- → Voucher — reviewed, approved, posted
- → Maintenance — its cost booked as an expense
- → Reports — income statement and trial balance
The result — Decisions made while the shift is still running
- ✓ Management sees the plant as it runs
- ✓ Recurring breakdowns surface on their own
- ✓ Stock and accounts keep pace with production
- ✓ Everyone looks at the same numbers
In their words — “Runs our entire day.”
— GP Plast
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