SARVA FOAM INDUSTRIES LIMITED · Rebonded Foam & Underlay Division

Daily Cost Console

Daily production cost tracking — sheets & underlay lines, by SKU

Import from Excel — one file, both lines

Reads "Sheet Production Data", "Round Block data", and "Labour and electricity status" from one file — whichever tabs are present. Fills raw materials, blocks, output/wastage, matched SKUs, labor, electricity, and glue for the date you pick below, all in one go. Nothing saves to the shared database until you click "Save daily log" at the bottom.
PurchasesRaw Material Bought Today ▼
MaterialQty (kg)Rate ₹/kg (actual invoice)Cost
Log what actually came in today at its real invoice rate — leave this empty on days with no delivery. This is what updates the weighted-average cost used to price the raw material consumed below and on future days.
SharedChipping & Foaming ▼
Raw material is now entered directly under each line below, since the two block types are made on separate machines and you know exact consumption for each. These two weights only set the split ratio for labor, electricity, and overhead — costs that are genuinely shared between the lines.
SheetsVertical + Circular Cutting ▼

Raw materials used — sheet blocks

MaterialQty (kg)% of QtyRate ₹/kg (ledger)Cost
Rate is the current weighted-average cost from the stock ledger, not typed in — it updates automatically as purchases come in. A * means no purchase has been logged for that material yet, so it's using the fallback rate from Settings; a ⚠ means this day draws more than the ledger shows in stock. If you've entered trim wastage above, its value is shown here as a credit against these materials. % of Qty is each material's share of the total raw material weight going into this line.

SKUs produced today

Spec (LxWxHxD)Output kg
UnderlayPeeling, Lamination & Packing ▼

Raw materials used — round (cylindrical) blocks

MaterialQty (kg)% of QtyRate ₹/kg (ledger)Cost
Rate is the current weighted-average cost from the stock ledger. If sheets and round blocks use the same material on the same day, both draw from one shared stock balance. If you've entered wastage above, its value is shown here as a credit against these materials. % of Qty is each material's share of the total raw material weight going into this line.

SKUs (rolls) produced today — pick a SKU to auto-fill its material cost, or leave as Custom and enter your own

SKUWt/roll (kg)Front ₹/rollBack ₹/rollBag ₹/rollGlue kg (auto)RollsOutput kg (blank=auto)
Selecting a SKU pulls its length/width/thickness/density and its front, back, and bag material types from the SKU master (Settings tab) and prices them using current material rates. Front/Back/Bag/Weight fields stay editable afterward if you need to override. Glue kg per SKU is no longer entered here — enter the total glue used today above, and it's automatically split across these SKUs in proportion to each one's rolls. Output kg auto-calculates as weight/roll × rolls unless you type an actual weighed figure. The shared foaming labor, electricity, and overhead are spread evenly across all roll SKUs by their output weight — raw material above is charged directly, not allocated.

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All logged days

DateSheets out (kg)Sheets avg ₹/kgSheets conv. ₹/kgSheets eff. % Underlay out (kg)Underlay avg ₹/kgUnderlay conv. ₹/kgUnderlay eff. % Total cost excl. raw & consum. (₹)

Period — opening/closing stock & sales apply to this range

Sheets vertical only. Blocks and sheets are treated as one pool of finished-goods kg at the same cost/kg. Production kg and cost/kg for this range are pulled automatically from the Daily Log (same weighted-average logic as the Reports tab) — everything else on this tab is stock and sales you enter.

Opening & closing stock — blocks + sheets combined, kg

Production this period

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Blended cost / kg

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Opening stock + production, weighted · exact, not rounded

Dispatched (derived)

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Opening + production − closing

COGS

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Dispatched kg × exact blended cost/kg

Gross profit

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Revenue

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Calculation breakdown — audit the numbers above, step by step

StepKgRateValue (₹)
The KPI cards above round every ₹/kg figure to whole rupees for readability. This table carries full decimal precision — the same precision the COGS and Gross Profit figures are actually computed from — so you can re-derive every number by hand and have it tie out exactly.

Sales by customer — fixed ₹/kg rate for the period

CustomerRate ₹/kgDispatched kgRevenue

Job-work deliveries — fully outsourced; partner ships to the customer and bills us

DatePartnerCustomerItem / SKUKgPartner bills us ₹/kgWe bill customer ₹/kgSales ₹Partner cost ₹Margin ₹

Job-work sales

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Partner cost

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Billed to us by partners

Job-work margin

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PartnerDeliveriesKgSales ₹Partner cost ₹Margin ₹
Job-work deliveries never pass through your own stock or the Daily Log, so they are kept out of the dispatched-kg reconciliation above. Their sales and partner cost are shown as separate lines in the breakdown and added into Gross profit. Enter both rates ex-GST.

Saved periods — this unit

PeriodProduction kgDispatched kgOwn COGSTotal revenueJob-work marginGross profitMargin %
Opening a saved period loads it back into the form above for editing. A new period's opening stock rate is suggested from the most recent earlier saved period's blended cost/kg — review and override it if the periods aren't contiguous.

Customers — this unit's list

CustomerRows in saved periodsStatus

Merge duplicate / misspelt customers

Pick the misspelt/duplicate name first, then the name to keep.

All units — the Reports metrics side by side, for any date range

Same calculations as the Reports tab, run on each unit's own rates, materials and logs. Each unit gets its own set of cards; nothing is combined across units. Other units' data is loaded once and kept for this session — use Reload data to pick up changes made elsewhere.

Current stock —

MaterialQty on hand (kg)Weighted avg cost ₹/kgStock value (₹)
Qty shown in red means consumption logged against this material has exceeded what the ledger shows was purchased or on hand — check for a missing purchase entry or an over-logged consumption day.

Purchase history — filter by period

Total purchased by material

MaterialPurchasesTotal qty (kg)Avg rate ₹/kgTotal cost (₹)

Purchase entries

DateMaterialQty (kg)Rate ₹/kgCost (₹)
Totals use the actual invoice rates entered in Daily Log → Purchases. They are separate from the weighted-average cost shown in Current stock above.

Electricity, wood & currency rates

The GBP rate is only used to show a £ figure alongside ₹ — it never affects the actual ₹ costing. Each day's entry locks in whatever this rate was when you saved it, so old dates' £ figures stay fixed even if you update the rate later; only new saves pick up a changed rate. "Refresh live rate" pulls the current rate from a public exchange service — review it and click Save settings to apply it.

Electricity and Wood rates below are effective-dated — add a new rate with the date it takes effect, and every day is costed using whatever rate was actually in force on that date, past or future. No existing data is retroactively affected unless you edit a past rate's value directly.

Labor rates — ₹ per person, applied to the headcount entered in Daily Log

Daily Log takes a headcount per stage instead of a total ₹ figure — the app multiplies by whichever rate was effective on that entry's date. Add a new rate below with the date wages actually changed — days before that date keep using the old rate, automatically.

Monthly overheads — spread across production days automatically

Allocation basis: shared foaming labor, electricity, and daily overhead split between Sheets and Underlay by weight of blocks each line drew from foaming — raw material is charged directly per line, not allocated. Within a line, the allocated share is spread evenly per kg across every SKU produced that day. These are also effective-dated — add a new figure with the date it takes effect (e.g. a rent increase from a specific month) and each day is costed using whatever was in force then.

Raw materials & opening stock — consumption is now costed by the weighted-average ledger, not a typed rate

MaterialFallback rate ₹/kgOpening stock (kg)Opening stock rate ₹/kg
Opening stock sets the ledger's starting point — the quantity and average cost of each material already sitting in the yard before you started logging purchases here. Fallback rate is only used if a material is consumed with zero purchase history and no opening stock (so the ledger has nothing to base a weighted average on). Once purchases are logged in the Daily Log, the ledger takes over automatically — see the Inventory tab for current stock and cost.

Trim/wastage entered in Daily Log is treated as reclaimed material: it's valued at the current ledger rate of whichever material is named "Rebonded" (matched automatically by name — keep that word in the material's name for this to work), credited back against that line's raw material cost, and added to that material's stock at the same rate — so reused trim isn't double-counted as a pure loss.

Production lines — for this unit

Turning this off hides every Underlay-specific screen for this unit — Daily Log's Peeling/Lamination stage, roll SKU pricing, and all Underlay figures on Dashboard, History, and Reports — and shared labor/electricity/overhead go 100% to Sheets. This can be switched back on later without losing any data: days already logged keep whatever they have, and new Underlay data just resumes flowing in from whenever you re-enable it.

Roll lamination & packing rates

These rates are effective-dated. When you pick a roll SKU in Daily Log (or import via Excel), the app looks up whichever rate was in force on that entry's date — not today's live rate — so backdating an old day's log always uses the pricing that was actually correct then. Already-saved batches keep their locked-in per-roll cost regardless; only a new selection re-derives from these rates.

Roll SKU master — front/back backing, bag type & dimensions per SKU

NameFront backingBack backingOuter bagLength (m)Width (m)Thickness (mm)DensityWt/roll
Front/back backing text is matched by keyword: "NONWOVEN" (+ "PRINT" for printed rate), "COREFRESH" (priced as Wilkies paper, + "WHITE" for the white variant — checked before the generic paper match, so any name containing both still gets the Wilkies rate), "PAPER" (+ "WHITE" for white rate), "PE FILM", or "FOIL". Outer bag is matched by "PRINTED" vs everything else (clear/color bag rate). Weight/roll = Length × Width × Thickness(m) × Density.

Data

Everyone who opens this page reads and writes the same shared database, so data is live across the team automatically. Export/import gives you a manual backup independent of that.