StageWhere money leaksWhat zappy.day does
1. Raw material storeStock is counted by eye, so material runs out mid-batch or is over-bought when prices are high.Material stock with minimum levels and supplier-wise rates. Consumption is posted automatically from each batch.
2. Batch weighingFormulas sit in one person's notebook. Small weighing errors change the product, and batch cost isn't known.Controlled formulas by grade, with batch sheets printed from the system and actual weights recorded. Batch cost uses current material rates.
3. Cooking & mixingTime and temperature aren't logged, so when a batch behaves differently nobody can tell why.Batch log with start, end, temperature readings and operator. Every batch gets a number that follows it to the customer.
4. Viscosity & lab checkResults stay in a lab register, and an out-of-range batch can still be filled and dispatched.Lab results are entered per batch, and filling is allowed only after the batch passes. Trends show drift before complaints start.
5. Filling & labellingContainers aren't linked to the batch, filled quantity isn't reconciled, and returnable drums go missing.Labels with batch codes printed from the system and filled quantity reconciled against the batch. Returnable containers are tracked by customer.
6. Dealer dispatch & creditMaterial keeps going to dealers who haven't paid the last three bills, and cash gets stuck in the market.Dealer credit limits with an automatic dispatch hold, scheduled payment reminders on WhatsApp, and dealer-wise outstanding on the owner's phone.
