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manufacturing_erp

Manufacturing

ERP for Manufacturing

ebizframe10 ERP addresses the needs of discrete as well as process manufacturing.

The Manufacturing functionality takes inputs from Sales Planning and Budgeting, from Material Management, from HR and is also linked to Finance, Costing and Fixed Assets as well as Maintenance functions.

ebizframe10 ERP Manufacturing Software provides a robust yet flexible system to meet the needs of diverse requirements of manufacturing environments.

Bill of Material: Bill of Material (BOM) functionality identifies a standard list of items, or components, required to produce various parent or child products (such as assemblies and sub-assemblies or compounds produced in-house which get further used for the final products). In BOM, a user can define the details of item in production and the processes required for production. The user can also define operations/processes where he can capture inputs, outputs, scrap and by-products or co-products.

The Bill of Material setup can be revised any time, and multiple versions of BOM can be maintained. Costing, Overheads and Quality Control (QC) parameters can also be attached with each operation for specific product for which the BOM is being created.

Tolerances based on principal input and planned production can be effectively monitored.

Engineering drawings, sketches, operation manuals, customer specifications or any other documents can be attached to the BOM using Document Upload facility.

The user can utilise Backflush option to generate automatic material issue based on the consumption at the shop floor.

ERP Manufacturing Setup

Operation: User can define multiple production processes as an operation. Operations can be of two types namely Production or Quality. If any operation is to be performed by third parties outside the factory, it can be marked as a sub-contracting operation else it will be treated as an in-house operation. User can create and select tools that are being used in the production of items. Tool utilization and tracking for maintenance can be done. Which operation can be performed on which all work-centers can be defined including set-up time linking specific operation to specific work-center.

Routing: Routing in ebizframe10 is a combination of erp manufacturing module processes, it can be sequential or parallel. It has direct integration with BOM. Routing can be revised several times for any alteration in sequence of processes. In case of parallel operations, the software tracks predecessor(s) necessary for subsequent operations. While defining Routing, user can add several operations and can allocate Work Centre to the particular route. Necessary documents can be attached to a particular route.

Shifts: It is possible to create multiple shifts with option to define Start, End and Break time. A shift can be marked as stretchable or otherwise. If there are multiple production units in the organization, ebizframe10 ERP system for manufacturing allows shifts for multiple units to be set up. Shifts can be named as per user convenience.

Product Creation: It is possible to identify whether an item is Sales item, Purchase item, it occurs as WIP, Stockable, whether it requires QC, etc. For example, if an item is marked as Purchase item, that item can be treated as Raw Material. If any item is marked as Sales item then that can be treated as a Finished Good. An item can have multiple behaviors, for example an item can be a Sales item as well as a Purchase item (for example in companies which also have a trading as well as manufacturing function). Item characteristics such as re-order level, safety stock, supplier lead time, pick order (FIFO, LIFO, Manual, FEFO), shelf life, minimum/maximum stocking level, alternate items are also captured. The logic of lot number generation for production is flexible in ebizframe and can be defined as per user preferences.

Manufacturing Work Centre:  A Work Centre is an aggregation of multiple work stations. Each Work Centre can have certain measurable characteristics, which can be captured using defined feedback parameters (such as temperature, humidity, pressure, etc.)

Staff can be associated with Work Centres as well as with Shifts. Material requirement areas defined in Materials Management can also be linked with the Work Centre for material consumption.

Work Station: A work station can be a machine, machine group, production line, labour or labour group i.e. anything that has individual capability to perform a specific, measurable operation or process. ebizframe10 user can select the production type as sequential or parallel. Whether a work station has a fixed capacity or it is variable can also be defined depending on the nature of operation, input, output, etc. Capacity can be defined in various ways such as optimum, maximum or minimum.

Like the Work Centre, a Work Station can also have certain measurable parameters, which can be captured using defined feedback parameters (such as temperature, humidity, pressure, etc.)

Since this Work Centre will also need to be linked to Maintenance as well as Fixed Assets, data such as Procurement details, AMC, Preventive Maintenance Schedule, etc. can be captured.

Production Planning: is offered as a part of the Planning Board functionality of ebizframe10. A Production Plan can be based on Sales Orders, Sales Forecast, Inward Sub-contracting Order, Make to stock, Safety Stock or any other need. It has direct integration with BOM and leads to the entire Material Requirement Planning (MRP) cycle. Forward as well Backward planning is possible. The Planning Board also helps in understanding cost optimisation after considering backward/forward planning. A Production Plan reflects a dynamic situation, hence multiple versions of Production Plan can be maintained

Production Order: Production Orders are a direct end result of Production Planning.  This forms the input for the Manufacturing function.

Capacity Planning: Based on the Production Order, process scheduling can be performed on various work stations. ebizframe10 has multiple algorithms for helping generate an optimised production schedule. These algorithms include Earliest Delivery First, Shortest Processing Time, First Come First Serve and Last Come First Serve. Capacity Planning also covers machine utilization, availability, etc. while performing scheduling. This results in Job Card creation for various manufacturing Work Centres.

Job Card: Job Card is the input for the Work Centre to perform specific operations based on the material required as per BOM. It can consist of manpower needs, instruction to the manufacturing team (such as scheduled downtime, QC parameters, feedback parameters, etc.). A Job Card is generated for specific operations. Tracking of individual operations across Work Centres can be done through Job Cards.

Route Card: In situations where individual operation tracking is not required, and more focus is on final product, a Route Card can be generated which will consist of manpower needs, manufacturing instructions and materials needed for all operations.

Job Execution captures all the details of items produced, raw material consumed, downtime if any, stock status, manpower used, actual production period and variances if any from the plan as well costing details. Job execution can be done for the entire planned quantity or can be done in multiple cycles. This also relates effectively with Manufacturing Accounting.

Group Production Plan: This option is used to combine common operations irrespective of multiple Production Orders. (For example, if there are several Production Orders, with certain common operations then through Group Production Plan, the user can combine these common operations for better efficiency.)

QC Process: Through this functionality, user can conduct either a complete check or a sample check of the material produced.  Online Quality Control (QC) can be performed during the desired stages of the Production Cycle. On the basis of input test parameters, user can match output with standards to approve or reject or rework the production output.

Shop Floor Feedback: Users can track all the measurements of machines during the Production Cycle. This can be used to analyse the health of the production facilities.

Costing: ebizframe10 has very detailed functionality for Costing. For manufacturing organizations, it is possible to link Manufacturing Costs (such as materials, labour and factory overheads), Non-manufacturing costs (such as SGA and interest) or corporate overheads to the products being made. The software provides a high degree of flexibility so that micro level view of cost constituents can be built for cost and profit optimization.

MIS: ebizframe10 Manufacturing ERP Software provides comprehensive MIS relating to BOM, Production Order, Job Card, Route Card, Workstation, Stock Status and QC related certificates. User can have graphical reports of Planned vs. Actual analysis, Downtime analysis, Shop Floor downtime and Top product manufactured. Periodical reports on various key production efficiency measures, monitoring of utility consumption, machine utilization, costing and many others are easily possible through ebizframe10 manufacturing erp systems.

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