How the system was built
Fugen ERP was written for a single terry towel plant: yarn store, ten looms, a dyehouse, finishing, stitching, packing and a finance department that reconciled everything by hand. The order of work was deliberate. Most ERP products begin as generic frameworks and are later adapted to factories by consultants. This one started with real documents, real batches and real payroll runs, then had the generic layer extracted from it. The demo still contains four months of coherent operating data, not three sample rows.
What the system does
The modules cover every department in a towel plant:
- Sales & Order Book: Quotation to invoice, with a live order book, delivery tracking and customer ledgers.
- Purchase & Suppliers: Requisition to payment, with GRN, incoming QC, supplier bills and payables in one chain.
- Inventory & Stores: One stock ledger for every store, batch and rack; no negative stock, no parallel spreadsheets.
- Production & Planning: Route every order through weaving, dyeing, finishing, stitching and packing, with real output per shift and machine.
- Quality Control: Incoming, in-process and final inspections, defect capture and a 4-point score.
- Product Costing: Cost per piece and per kilo built from actual material, wages, utilities and overheads.
- Finance & Accounts: Double-entry accounting that posts itself from operations; trial balance, P&L and balance sheet always tie.
- HR & Payroll: Attendance, shifts, leave, advances and payroll for monthly, daily-wage and piece-rate staff.
- Dynamic Approvals: Decide which documents need approval, at how many levels, by which role and above which amount.
- Business Control Centre: One screen for the whole business: money, orders, plant, quality, people and pending approvals.
- Activity Tracking & Session Replay: Know who logged in, from where, on what device, what they did and how long they spent on each screen.
- Roles, Users & Audit: Department-level roles with per-module view, create, edit and delete rights enforced in the API, not just the menu.
- Reports & Exports: Twenty-five plant and finance reports, filterable and exportable, with no report-writer licence to buy.
How we work with you
The process starts with a discovery call to understand your process. We then provide a written scope that states what is configured and what is built. Rollout is staged, department by department, with your own masters and opening balances. Support continues afterwards, with configuration changes typically completed within the same week you request them.
What we need from you
- A single point of contact who can make decisions and provide data.
- Access to your current documents: purchase orders, GRNs, job cards, payroll sheets, trial balance.
- Time from your team for training and testing; we provide the scripts and the environment.
- Willingness to stop parallel notebooks once the system is live.
What happens in week one
We set up a sandbox with your masters and opening balances. Your team logs in and starts entering live transactions alongside the old system. We monitor the data for consistency and train users on the screens they will use daily. By the end of the week, the trial balance should tie with your existing books, and the store keeper should be able to reconcile stock without a parallel notebook.
What we will not do
- Promise a two-day implementation.
- Sell you licences you cannot staff.
- Leave you with a system only a consultant can operate.
- Hide the fact that your process does not fit; we will tell you in the first call.
- Charge extra for reports or user training.
- Lock you into a contract that prevents you from exporting your own data.
Where the system stops
The software does not replace a production scheduler who understands loom capacity or a dye master who knows colour matching. It does not automate decisions that require human judgement, such as approving a credit note or adjusting a recipe. If your process requires a feature we do not have, we will say so upfront and suggest alternatives, including manual workarounds or third-party tools.
How the system is maintained
The engineering team is small and works directly with the plants. Bug fixes are released within 48 hours; small improvements are batched and released every two weeks. You can choose to apply updates immediately or defer them until your next quiet period. There are no forced upgrades, and your data remains your own.