Formula-driven cosmetic manufacturing ERP for Janki Herbals

Highsense Infotech built a cosmetic manufacturing ERP for Janki Herbals covering percentage-based formulations, separate base and packaging BOMs, enforced QC gates, two-way batch traceability and real per-batch costing.

The problem

Cosmetics are not made like general goods, and general-purpose software does not model them. A product is a formula expressed in percentages, not a fixed-quantity recipe - so scaling a batch from 50 kg to 200 kg has to recalculate every ingredient, not multiply a stored number. One bulk batch then splits into several pack sizes, each needing its own packaging bill and its own code.

Janki Herbals was holding formulations in spreadsheets and batch records on paper. Shade and fragrance variants were being created as entirely separate item masters, so the item list grew every time a shade changed. Raw and packing materials sat in one undifferentiated store. And because quality sign-off was a signature on a sheet rather than a state in a system, nothing physically stopped unapproved stock being packed.

What Highsense Infotech built

We built the formula as the centre of the system. Each product is stored as percentages per ingredient, so changing the batch size recalculates quantities automatically. The bulk recipe and the packaging bill are kept as separate BOMs - one base, many pack sizes - which is how cosmetics are actually produced. Shade and fragrance variants are handled as variants of the product rather than new item masters, so a shade change no longer clones the whole product record.

Quality became a real gate rather than a formality. QC pending, QC verify and QC approved are states the batch has to pass through, and stock that has not passed cannot be packed or dispatched. Batch numbers, manufacturing dates and expiry dates are generated with the batch, and ageing stock surfaces as an alert rather than a discovery at write-off.

Costing closes against the batch. Raw material, packing material, wastage and rework all post to the batch it came from, so margin per batch is a figure that can be read rather than estimated. Wastage is recorded with a reason, which turns it from a monthly surprise into a trend.

Inside the system

What changed

• ✓
  A batch size change recalculates the full formulation automatically, instead of being recomputed by hand in a spreadsheet.
• ✓
  Unapproved stock cannot physically reach packing or dispatch, because QC approval is a system state rather than a signature.
• ✓
  Any finished batch traces back to its raw-material lots and supplier, and any lot forward to every customer - the record an audit or a complaint needs.
• ✓
  Margin is known per batch, because material, packing, wastage and rework all close against it.
• ✓
  A new shade or fragrance is a variant, not a new item master, so the product list stopped growing with every variation.

Technology