कारखाना ऑप्स

पुष्पक सेफ एण्ड स्टील इंडस्ट्रीज

Standard Operating Procedures (SOP)

Staff Operations & User Manual

Complete day-to-day workflow instructions, step-by-step procedures, and role-wise morning-to-evening routines for Pushpak Safe & Steel Industries.

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Factory: पुष्पक सेफ एण्ड स्टील इंडस्ट्रीज Raipur Works
Step 01 Dashboard & Cockpit Daily Routine

Daily Morning Routine & Dashboard Cockpit

दैनिक सुबह की शुरुआत व मुख्य डैशबोर्ड

Start each business day by reviewing critical factory KPIs: active production jobs, low inventory alerts, today's expected returns, and outstanding token receivables.

Roles: Owner, Supervisor / Munshi, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Log in to Portal

Navigate to the app URL and sign in using your assigned staff credentials.

2 Phase 2

Review Low Stock Banner

Check if any foundational steel products, sheets, or locks are below minimum safety thresholds.

3 Phase 3

Inspect Active Deployments & Due Returns

Review which contractor challans have return dates scheduled for today or are overdue.

4 Phase 4

Check Order Token Receivables

Verify pending advance balances before releasing finished safes or almirahs to transport.

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Operational Standard: Pro-Tip: You can ask Munshi AI "Aaj kitne return expected hain?" or "Stock alerts dikhao" right from the bottom floating chat for instant vocal updates.
Step 02 Inventory & Catalog Master Data

Steel Furniture Master Catalog & Specifications

उत्पाद सूची, गेज विनिर्देश व मास्टर रेट्स

Register new manufactured steel furniture models, heavy safes, slotted racks, or raw sheets with technical dimensions, default rates, and replacement values.

Roles: Owner, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Access Products Screen

Click "Stock" in the sidebar, then click the "+ New Material" button at the top-right.

2 Phase 2

Enter Model & Size Specifications

Fill Product Name (e.g. "रॉयल डीलक्स 2-डोर अलमारी"), Size/Dimensions (e.g. "78H x 36W x 19D"), and Unit ("pcs").

3 Phase 3

Define Standard Rates & Replacement Value

Set standard daily/monthly hire rate or ex-factory valuation. Set Replacement Value for insurance/security ledger tracking.

4 Phase 4

Establish Safety Threshold

Input minimum available yard threshold (e.g. 5 pcs) to trigger automatic low-stock warnings on the dashboard.

5 Phase 5

Assign Visual Icon or Photo

Select a curated steel furniture vector icon or upload crisp high-resolution photography.

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Operational Standard: Point & Capture: On mobile phones, click "📸 Point & Capture" in the catalog to let Gemini AI vision automatically identify the model and pre-fill specifications.
Step 03 Workshop / Jobs Factory Floor

Workshop Job Cards & 6-Stage Fabrication Routing

कारखाना जॉब कार्ड व 6-चरणीय निर्माण प्रक्रिया

Manage the shop-floor assembly pipeline through 6 fabrication stages from cutting sheets to QC inspection and dispatch readiness.

Roles: Owner, Supervisor / Munshi

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Create Workshop Job Card

Navigate to "Workshop / Jobs" and click "+ New Job Card". Select the customer, product model, steel sheet gauge (e.g. 18G/20G), lock mechanism, and target dispatch date.

2 Phase 2

Print Traveler Slip for Shop Floor

Click "🖨️ Print Traveler Slip" to print the physical traveler sheet and attach it to the workshop clipboard or trolley.

3 Phase 3

Stage 1: Sheet Shearing & Bending (कटिंग व मोड़ाई)

Artisan cuts Tata Prime CRCA sheets on hydraulic shear and bends stiffeners. When finished, advance stage.

4 Phase 4

Stage 2: Arc & MIG Welding (वेल्डिंग व फ्रेमिंग)

Weld inner lockers, outer body, hinges, and tie-angles.

5 Phase 5

Stage 3: 7-Tank Chemical Pretreatment (केमिकल धुलाई)

Degreasing, derusting, phosphating, and passivation to ensure 100% rust-proof bonding.

6 Phase 6

Stage 4: Powder Coating & 200°C Oven (पाउडर कोटिंग)

Electrostatic dry powder spray and baking in hot oven.

7 Phase 7

Stage 5: Lock, Mirror & Fitting (ताला व फिटिंग)

Mount 8-lever Godrej lock, dial wheel, internal jewelry safe, and dressing mirror.

8 Phase 8

Stage 6: QC Pass & Dispatch Ready (डिस्पैच रेडी)

Final quality inspection, serial number badge riveting, and protective bubble packing.

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Operational Standard: View Modes: Switch between Table List View for high-density audits and the 6-Column Kanban Board for drag-and-drop visual tracking.
Step 04 Costing & Estimates Estimator

Steel Costing & Sheet Metal Estimator

स्टील लागत, शीट वजन व मार्जिन कैलकुलेटर

Calculate precise sheet metal weights based on surface area formulas (7.85 kg/m²/mm density), sheet scrap percentages, chemical powder coating, lock hardware, and minimum profitable MRP.

Roles: Owner, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Update Mandi Benchmark Rate

Click "📈 Update Daily Mandi Rate" to set the prevailing Raipur steel market price (e.g. ₹68.50/kg).

2 Phase 2

Select Product Preset or Custom Dimensions

Choose a standard model (e.g. 78"x36"x19" Almirah) or enter custom Height, Width, and Depth in inches.

3 Phase 3

Configure Gauge & Hardware

Choose primary body gauge (14G, 16G, 18G, 20G, 22G, 24G), lock mechanism (Godrej Ultra, Keypad, Brass Wheel), and powder coating type.

4 Phase 4

Review Financial Breakdown

System computes net sheet weight (kg), raw metal cost, labor overheads, coating fee, and suggests minimum floor price vs recommended retail MRP (25% margin).

5 Phase 5

One-Click Job Card Creation

Click "⚡ Create Job Card from this Estimate" to immediately spawn an active workshop job without retyping measurements.

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Operational Standard: Formula Standard: Pushpak Steel uses standard IS-513 cold-rolled sheet density ($7.85\text{ g/cm}^3$) with a 6% corner shear scrap allowance.
Step 05 Orders & Tokens Sales & Booking

Order Booking, Advance Token & Challan Dispatch

ऑर्डर बुकिंग, बयाना (टोकन) व डिलीवरी चालान

Book customer orders, record initial advance token payments with auto UPI QR generation, dispatch units from yard stock, and generate delivery challan vouchers.

Roles: Owner, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Enter Customer & Order Specs

Go to "Orders" and click "+ New Rental Dispatch / Order". Select or create the customer by mobile number and project site address.

2 Phase 2

Add Line Items & Quantities

Choose the product from the dropdown, enter quantity to dispatch, agreed hire/sale rate, and expected return or installation date.

3 Phase 3

Generate Delivery Challan

Submit to generate an official numbered Delivery Challan (e.g. DC-2026-0012). Yard available stock is immediately deducted in real time.

4 Phase 4

Collect Advance Token via UPI QR

Visit "Order Tokens". Click on the customer's order to reveal the dynamic UPI QR code pre-filled with the exact pending balance for instant phone scan.

5 Phase 5

Send WhatsApp Confirmation

Click the "💬 WhatsApp Reminder / Receipt" button to dispatch a pre-composed Hindi/English WhatsApp message directly to the customer.

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Operational Standard: Audit Rule: Delivery Challans must be signed by the driver and recipient before departure from the Raipur works.
Step 06 Safe Registry High Security

Safe & Almirah Key Registry with Lifetime Warranty

तिजोरी चाबी कोड रजिस्टर व 10-वर्षीय वारंटी प्रमाण पत्र

Confidential security registry recording vault serial numbers, blind key-cut codes, duplicate keys issued, sealed master envelope codes, and printable manufacturer warranty certificates.

Roles: Owner, Supervisor / Munshi

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Access Safe Registry

Navigate to "Safe Registry" in the sidebar (restricted to authorized personnel).

2 Phase 2

Record New Manufactured Safe / Tijori

Click "+ Register Safe / Almirah". Enter the unique stamped serial number (e.g. "PSK-2026-9041"), customer name, and model.

3 Phase 3

Log Key Code & Envelope Verification

Input confidential key code (e.g. "T-8840-X"), number of duplicate keys provided (default: 3), and sealed red wax envelope number.

4 Phase 4

Set Lifetime Warranty Period

Specify warranty duration (default: 10 Years). System automatically calculates warranty expiration date.

5 Phase 5

Print Official Warranty Certificate

Click "📜 Print Warranty Certificate" to print the ornate certificate complete with security watermark and QC pass hologram area.

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Operational Standard: Security Protocol: Never disclose key codes over phone. Require customer to present original warranty certificate and Aadhaar verification for key duplicate requests.
Step 07 Stock & Inventory Inventory Audit

Yard Stock Inward Adjustments & New Purchases

स्टॉक आवक-जावक, नई खरीद व भौतिक मिलान

Maintain real-time yard inventory counts. Record new manufactured batches inward, supplier deliveries, scrap deductions, and physical audit recount corrections.

Roles: Owner, Supervisor / Munshi

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Navigate to Yard Stock

Click "Stock" in the sidebar to view the Material Fleet Breakdown table.

2 Phase 2

Switch to Stock Adjustment Tab

Click the "⚡ Stock Quantity Adjustment (आवक-जावक)" tab, or click "[ ⚡ Adjust Stock ]" on any row in the table.

3 Phase 3

Select Movement Type

Choose "📥 New Yard Purchase / Production Batch (+ Stock)" for newly finished products, or "⚖️ Stock Count Audit Correction (+ / -)" for physical recounts.

4 Phase 4

Enter Quantity Delta

Type positive quantity (e.g. +20) to add units to yard stock, or negative (e.g. -2) to record scrap or write-offs.

5 Phase 5

Provide Audit Note & Submit

Input reference reason (e.g. "Batch #14 powder coating completed" or "Monthly physical count audit"). Click "Record Stock Adjustment".

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Operational Standard: Immutability: Pushpak Steel logs an immutable ledger entry for every adjustment. Unexplained manual edits without reference notes are forbidden.
Step 08 Returns & Challans Returns & QC

Return Tracking, Damage Inspection & Settlement

माल वापसी, टूट-फूट निरीक्षण व अंतिम निपटारा

Process returned hire materials or warehouse racks at the yard gate. Inspect pieces for good condition, repairable damages, or lost units with automated fee billing.

Roles: Owner, Supervisor / Munshi

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Locate Delivery Challan

Go to "Orders" and find the active contract by challan number or customer name.

2 Phase 2

Open Return Inspection Form

Click "Record Inward Return" on the rental details page.

3 Phase 3

Enter Physical Inspection Counts

For each line item, input quantity received in Good Condition, Damaged Quantity (requiring welding/straightening), and Lost Quantity.

4 Phase 4

Automated Charge Computation

If yard damage rules are enabled, system automatically generates repair charges and full replacement value charges for lost equipment.

5 Phase 5

Print Return Voucher

Click "Print Return Voucher" to hand a signed copy to the returning transport driver.

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Operational Standard: Partial Returns: The system supports multiple partial returns across weeks; contracts remain "Active" until 100% of pieces are accounted for.
Step 09 Munshi AI AI Assistant

Conversational AI Munshi Assistant & 1-Tap Actions

मुंशी जी वॉयस/चैट असिस्टेंट व 1-टैप एक्शन

Use natural language voice and text inquiries in Hindi or English to check job statuses, calculate sheet costing, retrieve safe key codes, check token balances, and execute 1-tap actions.

Roles: Owner, Supervisor / Munshi, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Open Munshi Cockpit or Floating Widget

Click "मुंशी जी" in the sidebar for the full cockpit, or tap the floating Munshi avatar button on any screen.

2 Phase 2

Speak or Type Your Query

Examples: "JC-2026-0001 status kya hai", "Almirah costing 20G", "Ramesh token balance", or "Safe key code PSK-TEST-8801".

3 Phase 3

Interact with Dynamic Rich Cards

Munshi renders interactive visual cards for job status, steel costing breakdowns, safe details, and customer khata balances.

4 Phase 4

Execute 1-Tap Action Callbacks

Click in-chat buttons like "[ Advance to Next Stage 🚀 ]", "[ Create Job Card from Estimate ⚡ ]", or "[ Record ₹5,000 Token Payment 💰 ]" to take action instantly without navigating away.

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Operational Standard: Voice Input: Click the microphone icon to speak directly in Hindi or Chhattisgarhi; Munshi automatically transcribes and resolves your intent.
Step 10 Reports & Accounting Accounting

Financial Balances, Fleet Valuation & Tally Prime XML Export

वित्तीय लेज़र, फ्लीट मूल्यांकन व टैली प्राइम एक्सपोर्ट

Monitor customer dues, evaluate total capital tied up in manufactured inventory, audit live site deployments, and export XML accounting vouchers into Tally Prime or Busy.

Roles: Owner, Billing Staff

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Contractor Balances Tab

View total charges debited, cash/UPI payments received, and net balances due per contractor.

2 Phase 2

Equipment Fleet Valuation Tab

Inspect units in yard vs out on rent, individual replacement values, and grand total capital fleet asset valuation.

3 Phase 3

Active Deployments Tab

Check which customer sites currently hold factory equipment, issue dates, and expected returns.

4 Phase 4

Tally & Accounting Export Tab

Select date range and voucher type (Sales vs Receipts), then click "Download Tally XML Voucher" to import directly into Tally Prime.

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Operational Standard: Tally Standard: The export generates standard XML ENVELOPE structure compatible with Tally Prime 3.0+ and Busy Accounting software.
Step 11 Data Onboarding Migration

Staged CSV Data Onboarding & Migration

सीएसवी डेटा आयात व सत्यापन (25-75 लेआउट)

Safely migrate legacy Excel/CSV datasets for products, customer registries, and running contracts with two-stage validation and inline error correction before committing.

Roles: Owner

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Select Dataset Type (Left 25% Panel)

Choose between Materials & Opening Stock, Customers & Site Registries, or Active Running Rental Contracts.

2 Phase 2

Upload CSV File

Choose your .csv file following the column format guidelines shown on the sidebar card.

3 Phase 3

Preview & Validate Staged Rows

System parses every row. Valid rows are highlighted in green; syntax or missing data errors are highlighted in amber/red.

4 Phase 4

Inline Correction & Commit

Correct any faulty values directly in the preview table. Once all rows are valid, click "Commit to Live Database".

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Operational Standard: Safety Shield: Staged imports do NOT mutate live stock or customer records until you explicitly click "Commit to Live Database".
Step 12 Settings & Control Administration

Business Profile, Yard Policies & Staff Permissions

व्यावसायिक प्रोफ़ाइल, नियम व कर्मचारी अनुमतियाँ

Configure legal business name, GSTIN, bank/UPI details, rental monthly divisor rules (30-day vs actual month), damage fee policies, and role-based capability matrices.

Roles: Owner

⚙️ Step-by-Step Operating Checklist (दैनिक संचालन निर्देश)

1 Phase 1

Business Profile

Set official enterprise trade name ("पुष्पक सेफ एण्ड स्टील इंडस्ट्रीज"), Raipur works address, GSTIN, bank IFSC/account, and UPI ID.

2 Phase 2

Rental Calculation Rules

Configure monthly calculation basis (calendar month vs 30-day fixed divisor) and weekend holiday chargeability.

3 Phase 3

Yard & Shop Policies

Set default advance deposit percentage, late return grace days, and auto-generated damage assessment fees.

4 Phase 4

Role Permissions

Enable or restrict staff capabilities (e.g. restrict staff from waiving charges or deleting master records).

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Operational Standard: Legal Documents: Changing your business name or GSTIN in settings immediately updates all future delivery challans, warranty certificates, and invoices.

💡 Pushpak Safe & Steel Fast Keyboard & Navigation Shortcuts

Press Tab or click navigation icons
मुंशी जी AI Voice Tap mic icon in bottom chat
Quick QR Scan Tap QR icon on top-right bar
1-Tap Job Advance Click ⚡ Advance on Job row
Tally XML Export Reports → Tab 4 → Download