Microsoft Dynamics 365 ERP for Film & Flexible Packaging – Cut Waste, Boost Cost Accuracy
Effortlessly manage complex materials, improve cost accuracy, and maintain inventory balance
ERP Solution for Film and Flexible Packaging built on Microsoft Dynamics 365 Finance and Operations
Managing unique film and flexible packaging orders is tough. Every reel counts, and small inefficiencies hurt profits. Manual errors in costing, wasted material, and poor traceability make it hard to deliver on time. Samadhan’s ERP for Film and Flexible Packaging solves this right out of the box. The ERP solution is built on the robust platform of Microsoft Dynamics365 Finance and Operations.
Stop guessing on quotes. Design products with precise layers, GSM, and thickness. The system instantly generates accurate Bills of Materials, calculates ink/adhesive needs, and gives real-time cost estimates. No more copying data between sales and production, approved quotes become ready-to-run designs in seconds.
Smart deckle optimization combines similar jobs to slash waste on your extrusion lines. Track every reel from raw material to finished product, know exact weight, length, and production details instantly. Real-time shop floor control shows machine status, waste, and stoppages as they happen. Quality checks and preventive maintenance are built in, so you catch issues before they delay deliveries.
Plan dispatches from one dashboard. See shipment readiness, coordinate with logistics, and hit deadlines. Financial controls ensure credit management and compliance. Samadhan Film and Flexible Packaging ERP solution connects everything:
Product design, production, quality, and finance, all in one place. Cut wastages, reduce downtime, and win more orders with clear visibility from quote to delivery.
How a Flexible Packaging Manufacturer Moved from Complexity to Control
A leading flexible packaging manufacturer in the UAE was operating with disconnected systems, manual adjustments, and limited visibility across departments. Planning, production, sales, and costing worked, but not together. That made the margin control difficult and slowed decision-making. They shifted to one integrated platform, bringing operations onto a single, connected system.
The result:
- Smoother flow between planning and production
- No more reconciliation between systems
- Clearer cost visibility per order
- Better throughput and stronger control over margins
- Faster, and more confident operational decisions.
This was not just a system upgrade. It changed how the plant was managed day to day.
Why This Matters for You
If you are responsible for output, cost control, or delivery performance, you already know the pressure: rising material costs, tight margins, production working hard but profits not fully reflecting it, and too much dependency on manual checks and experience. If you are exploring ways to improve visibility, efficiency, and profitability across your operations, this case study and the most important pain-points faced by manufacturers which offers practical insights you will not want to miss.
Download the Asset and see how the transformation actually happened ⇒
Accurate Costing
Product Design Interface captures varied raw material and routing costs.
Inventory Optimization
Operation-wise Work In Progress (WIP) quantity tracking. Utilize barcode/QR code-enabled labels for precise reel management and traceability.
Enhanced Traceability
Facilitate reel tracking based on jumbo size, deckle combinations, and production sets.
FAQs
Everything you need to know about the Film & Flexible Packaging (Finance & Operations)
Item Master & Data Management
Do you face issues with duplicate items in your master data—especially with variations in substrate, size, or customer specs causing confusion and inventory errors?
Do you face issues with duplicate items in your master data—especially with variations in substrate, size, or customer specs causing confusion and inventory errors?
Many manufacturers struggle with bloated item masters due to duplicates, leading to:
- Confusion during order entry
- Inventory mismanagement
- Difficulty in analysis and reporting
Our customized D365 F&O solution includes intelligent item master controls that prevent duplication by:
- Smart validation rules based on specifications
- Standardized naming conventions
- Variant management for size/thickness combinations
- Single source of truth for procurement, production, and sales
Multi-Layer BOM & Routing Cost Calculation
Can you accurately track costs from granules through extrusion, printing, lamination to finished goods? Or is it manual and error-prone?
Can you accurately track costs from granules through extrusion, printing, lamination to finished goods? Or is it manual and error-prone?
Flexible packaging involves complex multi-stage processing:
- Granules → Extrusion → Printing → Lamination → Slitting → Pouching
- Manual cost roll-ups are error-prone and time-consuming
- Difficulty in tracking yield loss, scrap, and rework at each layer
Our software provides automated multi-layer BOM and routing cost calculation:
- Real-time cost roll-up from raw material to finished goods
- Stage-wise yield tracking and scrap accounting
- Automated absorption of conversion costs at each process layer
- Accurate COGS calculation for profitability analysis
Pre-Sales Costing & Quotation Management
How quickly can your sales team generate accurate quotes considering multi-layer BOM, process charges, cylinder costs, and wastage?
How quickly can your sales team generate accurate quotes considering multi-layer BOM, process charges, cylinder costs, and wastage?
Pre-sales teams often struggle with:
- Dependency on production/costing teams for estimates
- Manual calculations leading to errors and delays
- Difficulty factoring in cylinder amortization, setup charges, minimum order quantities
- Inconsistent pricing leading to margin leakage
We’ve customized a Pre-Sales Costing Module that enables:
- Instant cost estimation with multi-layer BOM simulation
- Configurable rules for wastage, setup, and tooling charges
- What-if analysis for different substrates, volumes, and specifications
- Direct conversion to sales quotation and order
- Audit trail of all assumptions and approvals
Multi-Level Packaging Information & Weight Calculations
How do you manage packaging hierarchy from pouches to cartons to pallets? Can you auto-calculate net/gross weights including core details?
How do you manage packaging hierarchy from pouches to cartons to pallets? Can you auto-calculate net/gross weights including core details?
Packaging specifications are critical but often managed manually:
- Multiple levels: Pouch → Inner Box → Carton → Pallet
- Core specifications (diameter, weight, material) affecting net/gross weight
- Customer-specific packaging requirements
- Difficulty in generating accurate shipping documentation
- Errors in freight calculations due to wrong gross weights
We’ve built a Multi-Level Packaging Master that captures:
- Complete packaging hierarchy (up to 5 levels)
- Core details: Type, diameter, weight, material
- Automatic net and gross weight calculation at each level
- Packaging material auto-consumption during production
- Integration with shipping documents and freight calculation
- Customer-specific packaging templates for repeat orders
WIP Sales at Intermediate Stages
Do you ever need to sell semi-finished inventory like printed rolls or laminated reels or printed laminated film? How do you price and account for it?
Do you ever need to sell semi-finished inventory like printed rolls or laminated reels or printed laminated film? How do you price and account for it?
Most ERP systems don’t handle WIP sales well:
- No mechanism to price and sell intermediate products
- Difficulty tracking what’s available at each stage
- Manual workarounds create accounting and inventory issues
Our Product Data Sheet customization allows you to:
- Define sellable WIP at any stage (printed, laminated, slit, etc.)
- Automatically calculate costs and set pricing for intermediate products
- Create sales orders directly from WIP inventory
- Maintain proper inventory and financial accounting
- Track profitability on WIP sales vs. scrapping
Combining Production Orders in Film & Flexible Packaging
Can production orders with the same micron and description be combined in Dynamics 365 F&O? How can we handle situations in Samadhan ERP?
Can production orders with the same micron and description be combined in Dynamics 365 F&O? How can we handle situations in Samadhan ERP?
Problem :
• Manufacturers often receive multiple production orders with identical specifications.
• Running these separately increases machine setup time and reduces efficiency.
• Material usage is harder to optimize when orders aren’t consolidated.
• Manual workarounds can cause scheduling delays and tracking issues.
• Finance and inventory teams struggle with duplication and unclear reporting.
Resolution :
• Dynamics 365 F&O customization allows merging orders when micron and description match.
• Combined runs reduce machine setup effort and save production time.
• Material usage is optimized by consolidating batches.
• Each original order remains traceable within the system.
• Inventory and financial records stay accurate and aligned with production activity
Why us?
Looking for solutions for flexible packaging? This is why Samadhan is the best option for you.
Comprehensive Solution Integration
Our solution seamlessly integrates with Microsoft Dynamics 365 Finance & Operations and Business Central, covering all aspects from pre-sales to production.
Proactive Purchase Planning
Leverage our purchase planning engine that uses forecasts, sales orders, and historical trends to streamline sourcing and optimize inventory.
Real-Time Insights
Gain insights into material requirements, including film usage in kilograms and meters, average cost per kilogram, and profitability of finished products.
Paperless Manufacturing Management
Implement a paperless system for job cards with barcodes, enhancing identification, accuracy, and transparency across operations.
Expertise in Flexible Packaging
With our deep understanding of the flexible packaging industry, we provide tailored solution that address your unique challenges and drive operational excellence.
