The test record and the pump go their separate ways
In most pump plants the test data and the production data live apart. The test room keeps its records — on paper, in a register, in a spreadsheet, or in the testing software. Stores keeps a stock book. Despatch keeps an invoice file. Warranty keeps a claims file. Each is kept carefully, and none of them can answer the question that actually comes up.
That question is always the same. A pumpset comes back from a dealer eighteen months after despatch with a complaint about discharge. What was its serial number, when was it tested, what did it read on the bench that day, which motor went into it, which batch of impellers was running that week, and has anything else from that batch come back?
Answering it by hand takes a day and three people. Answering it from one system takes a minute, and the answer is the same one every time it is asked.
What we build
We build plant software for pump and motor manufacturers, either as a complete ERP or as the specific modules a plant is missing. It is built around the serial number, because that is the thread that runs through a pump's whole life, and it connects to the testing software so that the test record is attached rather than filed.
We do not sell a boxed product with your process bent to fit it. We study what your plant does now, write down the scope, and build to it.
Suited to
- Pump and motor plants with a BIS licence
- Plants running more than one line or more than one unit
- Manufacturers selling through a dealer network
- Plants where the test data is already in Tester
What a pump plant usually asks for
Taken together or separately. Most plants start with two or three and add the rest over a year.
Production planning
- Work orders by model and batch
- Line and shift loading
- Progress against the plan
- Rework and scrap recording
Inventory and stores
- Raw material, bought-out and finished stock
- Goods inward against purchase orders
- Issue to line against work orders
- Reorder levels and stock ageing
Bill of materials
- BOM by pump model and variant
- Impeller, casing, shaft and motor mapping
- Costing roll-up from the BOM
- Revision history
Serial number traceability
- Serial number allotted at assembly
- Test record attached to the serial number
- Motor serial held against the pumpset
- Component batch held against the build
Despatch and invoicing
- Despatch note against the sales order
- GST invoice with HSN and e-way bill details
- Serial numbers printed on the despatch document
- Transporter and delivery tracking
Warranty and service
- Claim registered against the serial number
- Original test record shown with the claim
- Repair, replacement and credit note
- Failure analysis by model and batch
Dealer orders
- Dealer order entry and order status
- Price lists and scheme discounts
- Outstanding and credit limit
- Claim submission by the dealer
Reports for management
- Production against plan by model
- Test pass rate by model, line and shift
- Stock valuation and movement
- Warranty cost by model
Access and audit
- Role-based access by department
- Who changed what, and when
- Approval steps where they are needed
- Read-only access for auditors
Built in stages, against a written scope
An ERP that arrives all at once arrives badly. We build in stages: the module that hurts most first, in use and settled before the next one starts. Each stage has a written scope, a fixed price and a date.
The first stage is always a study. We spend time in the plant with the people who will use the software, and we write down what happens today, including the parts that are not in anyone's procedure. That document is what the scope is built from, and you see it before anything is quoted.
Data from your existing registers and spreadsheets is brought in where it is worth bringing. Where a plant has years of test records in Tester, those come across with the serial numbers intact.
Training is given to each department on its own screens, not as one long session for everybody.
Technology
- Cloud-hosted on AWS, so the plant does not run a server room, and a second unit can be added without new hardware.
- Role-based access, so the stores clerk, the test room operator and the accountant each see their own work and nothing else.
- Scheduled backups, held away from the machine that produced them, with a documented restore.
- Works on the plant network and on a phone browser for the despatch gate and the service engineer.
- Connects to Tester, so test records attach to serial numbers without re-entry.
Request a demonstration of Tester
Tell us your pump types and the IS standards you test to. We will arrange a demonstration for your plant, in person in Tamil Nadu or online anywhere in India.