Overview
Deepak Products (Jamnagar, est. 1985, ISO 9001:2015) fabricates precision brass components — terminal pins, MCB parts, modular socket/switch parts — from sheet, coil and rod stock. The ERP models the real factory: raw brass bought by weight becomes finished parts counted in pieces, every stage carries the supplier's heat number for traceability, quality checks are mandatory before anything moves, and the dies that stamp the parts wear out and get tracked automatically.
What makes it custom
- Tool-wear tracking — a module ERPNext doesn't ship: dies accumulate cycles automatically from production and raise wear alerts.
- Heat-number genealogy — every finished pin traces back to the exact supplier brass lot.
- Hard-stop quality gates — no dispatch without a passing inspection (the ISO control).
- Role-scoped branded logins — nine staff logins, each seeing only their slice, entered through a Deepak Products door.
The cast
The end-to-end flow
One order, followed from customer PO to shipped goods. Each box is a stage owned by a role; the batch (heat number) threads through all of them.
Cross-cutting the whole flow
Tooling — the dies on PRESS-01 / FORM-02 / PLATE-03 gain cycles on every Job Card and flag wear · Traceability —HEAT-2607-A → DP-BLANK-00001 → DP-FORM-00001 → DP-PIN-00001 · Scrap — byproduct weight captured at each stage.The 9 roles
Each person signs in at /dp-login, lands on the Deepak Products dashboard, and sees only the modules their job needs. "Can do" is enforced by permissions; "Sees" is enforced by module scoping.
Sales Coordinator
liveStore Manager
liveProduction Manager
liveShop Floor Operator
liveTooling Engineer
alertQuality Inspector
gatePre-Dispatch
liveDispatch
liveManagement
read-onlyThe 7-act demo script
A ~15-minute walkthrough that tells the whole story. Sign in and out at /dp-login between acts (logout returns you there automatically). Every account uses DpDemo@2026.
The order comes in
sales@- Sign in as Sales Coordinator → land on the Deepak Products dashboard.
- Open Sales Order SAL-ORD-2026-00007 — Metro Switchgear Ltd, 2,000 brass terminal pins, ₹10,000.
- Point out: this is the demand that will pull the whole factory. Sidebar shows only Selling · Stock — no accounts, HR or clutter.
Brass arrives — traceability begins
store@- Sign in as Store Manager. Open the Material Request MAT-MR-2026-00001 (200 Kg brass to procure).
- Show the raw item Brass Sheet-CuZn37 — bought by weight (Kg), tracked by heat/lot batch (e.g. HEAT-2607-A).
- Explain: from this moment the supplier's heat number is stamped onto everything made from it.
Plan the production
production.manager@- Sign in as Production Manager. Open the two waiting Work Orders MFG-WO-2026-00007 / 00008.
- Open a BOM to show the multi-level bill: Pin → Formed part → Blank → Brass Sheet, each stage with its machine and scrap.
- Show the dashboard's order-progress — planned vs produced ("how much of the 1-lakh order is done").
On the floor — and the dies wear
shopfloor1@ · tooling@- Sign in as Shop Floor Operator. Complete a Job Card on PRESS-01 (enter completed qty, submit).
- Now sign in as Tooling → open DIE-PRESS-1000: its cycle count rose automatically from that Job Card, and it's flagged Warning at 86% of rated life.
- Show the dashboard "Tools – Wear Warning" card now reads 1, and the Tooling engineer has a ToDo to service it.
The quality gate (the ISO moment)
qc@- Sign in as Quality Inspector. Open the pending inspection MAT-QA-2026-00002 for the finished pins.
- Show the tolerance template DP Pin Dimensional: pin dia 2.00 ±0.02 mm, length 12.00 ±0.10, plating 8–12 µm — a reading out of band auto-rejects.
- The kicker: try to create a Delivery Note for pins without a passing inspection → ERPNext blocks it: "Quality Inspection is required for Item DP-PIN-1000."
Stage & ship
predispatch@ · dispatch@- Sign in as Pre-Dispatch → stage the Delivery Note against the customer order and the inspected batch.
- Sign in as Dispatch → submit/ship it (only possible because QC is green).
- Print the branded Delivery Challan and QC Certificate (Deepak Products / ISO 9001:2015 letterhead).
The big picture + the trace-back
management@- Sign in as Management → the control-tower dashboard: finished pins in stock, open orders, scrap Kg, tools by status, work-orders by status.
- Finale — open a finished batch DP-PIN-00001 and trace it backward to the supplier heat HEAT-2607-A.
- Note Management can see everything but change nothing — clean read-only oversight.
Logins & navigation
| Go to | URL | Who |
|---|---|---|
| Branded staff login | erp.trayaam.com/dp-login | All 9 role accounts |
| Admin login | erp.trayaam.com/login | Administrator (unchanged, full access) |
| Control-tower dashboard | /app/deepak-products | Everyone lands here after sign-in |
| Role | Account (@deepakproducts.demo) | Password |
|---|---|---|
| Sales Coordinator | sales@ | DpDemo@2026 |
| Store Manager | store@ | |
| Production Manager | production.manager@ | |
| Shop Floor Operator | shopfloor1@ | |
| Tooling Engineer | tooling@ | |
| Quality Inspector | qc@ | |
| Pre-Dispatch | predispatch@ | |
| Dispatch | dispatch@ | |
| Management | management@ |
Login behaviour
Staff sign in on the green Deepak Products page and are returned to it on logout. The admin/login is untouched. These are placeholder demo emails — swapping in real employee addresses at go-live is a quick change, no rebuild needed.Functional features by module
Manufacturing & inventory
Multi-level BOM models the weight-to-piece transformation: Brass Sheet (Kg) → Blank (Nos) → Formed part → Finished pin, each stage its own bill with an operation, a machine, and a scrap (secondary) output. Production Plan explodes the levels; Work Orders drive Job Cards on the three workstations.
| Object | Detail |
|---|---|
| Items | Brass Sheet-CuZn37, DP-BLANK-1000, DP-FORM-1000, DP-PIN-1000, Brass Scrap |
| Machines | PRESS-01 (blanking), FORM-02 (forming), PLATE-03 (plating) |
| Scrap | Captured by weight at each stage as a BOM secondary item, valued for resale |
Tooling — cycle counts & wear alerts custom-coded
A brand-new Tool DocType (dies, punches, inserts, moulds, fixtures) with a rated life and a read-only cycle count. When a Job Card is submitted, every tool on that machine gains the produced quantity in cycles (logged to Tool Usage Log), and at 80% / 100% of rated life the status flips to Warning / Due for Service with a ToDo to the Production Manager and Tooling. A daily job re-scans as a safety net. Nothing is logged by hand.
Quality & compliance (ISO 9001:2015)
Quality Inspection Templates carry numeric tolerance bands (min/max) per parameter; a reading out of band auto-rejects. Stock Settings enforce a hard stop — a receipt or delivery of an inspection-required item cannot submit without a passing inspection. Verified with a negative test: an ungated delivery is refused outright.
Traceability — heat-number genealogy
Every raw, WIP and finished item is batch-tracked; the raw batch is the supplier heat number. Each manufacture entry links consumed and produced batches, giving an unbroken chain HEAT-2607-A → DP-BLANK-00001 → DP-FORM-00001 → DP-PIN-00001 — walkable in both directions for recalls and audits.
Dashboards & branded print
The Deepak Products workspace surfaces 7 KPI cards (finished pins, open work/sales orders, scrap Kg, tools by status) + 2 charts + workflow navigation. Three Jinja print formats — QC Certificate, Job Card Traveler, Delivery Challan — all render on the Deepak Products / ISO letterhead.
Technical architecture
The genuinely custom logic lives in a versioned Frappe app; everything else is scoped configuration of stock ERPNext. Nothing is hand-edited in production — the app is baked into a custom image and re-applied on migrate.
| Layer | How it's built |
|---|---|
| Platform | ERPNext v16.26.2 / Frappe 16.25 in Docker (frappe_docker) on an Ampere/arm64 host; Traefik TLS; single site erp.trayaam.com. |
| Custom app | deepakproducts 0.0.1 — DocTypes Tool, Tool Usage Log; hooks for cycle-count/wear, branding, login guard, after-migrate. |
| Image & deploy | Baked into erpnext-deepak:v16.26.2 (pip-install, no node needed); compose pins it with pull_policy: never; backup before every deploy. |
| RBAC | 9 roles; staff are normal System Users + one role + Block Modules for sidebar scoping + a 225-entry Custom DocPerm matrix for data scoping. |
| Login / white-label | Branded /dp-login posts to Frappe's own /api/method/login; logo/name/favicon rebranded; "Built on Frappe" removed. |
| Durability | Workspace shipped as a native file; an after_migrate hook re-applies branding and re-gates admin workspaces so a migrate never regresses them. |
Why staff are System Users, not restricted "User Types"
The obvious tool — Frappe's restricted User Type — strips the implicit Desk User role, which the standard list filters, kanban and saved views require. That caused the "Insufficient Permission for List Filter" errors during testing. The fix: normal System Users (which keep Desk User, so the Desk works fully) scoped by Block Modules + Custom DocPerm. Same "only your world" result, none of the breakage.
How the logout-to-/dp-login works
Signing in on /dp-login drops a dp_portal cookie. A guard on the update_website_context hook (which runs in the render path where redirects are honored) forwards a cookie-bearing Guest hitting /login to /dp-login. Admins never get the cookie, so their /login is unchanged.
Notes & caveats
- Demo data posts real inventory/accounting into the Trayaam company; it's reversible via Cancel if you want pristine books for go-live.
- The only residual "Frappe" string is an invisible HTML comment in a core file — not visible to any user; removing it would mean patching ERPNext core.
- Placeholder @deepakproducts.demo accounts are swapped for real employee emails at go-live — same mechanism, no rebuild.
- Still upcoming per the roadmap: mobile shop-floor barcode scanning (PWA), a heat-genealogy report screen, and the security-hardening pass.