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Manufacturing Management

ERP for Manufacturing includes the Repetitive/Just-in-Time Production Scheduling, Work Order Management, Capacity Management, Capacity Planning & Scheduling, Production Tracking, Costing, Scrap, Labor Reporting, and Make to Order Kits Applications.

Repetitive / Just-in-Time Production Scheduling

Repetitive and Just-In-Time Production Scheduling and Reporting is designed to provide a simpler method of planning, scheduling and reporting manufacturing activity than that offered by the work order management module. Daily production schedules may be prepared in advance of production and reported against, or production may simply be reported as it occurs with no supporting schedule. The same database of items, lot numbers and on hand quantities, bills, routings and tools etc. is used in the repetitive and work order applications and consumption of material and labor data is written to the same historical data repositories (perpetual inventory, perpetual labor, tool usage history, manufacturing - G/L interface, etc.). There is no "hidden work order" number to identify production runs; this is done by end item and lot number or date. A spreadsheet like interface can be used to set schedules in a simple and familiar way.

Work Order Management

The Work Order Management application is the core of a complete shop floor control system. Once an order is launched through either manual or auto-release procedures, the application provides a host of mechanisms for controlling work order related material, labor, tooling and service costs. The system allows standards to be maintained by order. This is accomplished by creating a released bill and permitting adjustments in material, labor, service and tooling requirements, without effecting other jobs or standard bills of material and routings. In finished goods receipts, material may be directed from the work order into inventory or directly into another work order. The Work Order Management allows the user to accumulate manufacturing costs in as much detail as needed.

Capacity Management

Capacity Management operates continuously within the database without any user intervention required. The plan exists simultaneously as actual capacity requirements as defined by released work orders and authorized repetitive production and also as planned work orders and planned repetitive production. As planned production is scheduled and in turn completed, the capacity plan is automatically updated to reflect the current status. The impact of changes in the manufacturing schedule at any level can be seen reflected immediately in the capacity requirements. Examine capacity requirements by department, work center, production line, work order, manufacturing schedule, etc.

Capacity Planning & Scheduling

Our Capacity Planning and Scheduling feature provides you with a “dashboard” type screen that displays manufacturing work centers by several user-defined criteria. You can quickly view work centers that are near or over capacity and re-schedule work orders as needed. This is done as a snapshot outside of the current manufacturing schedule, allowing for what-if scenarios prior to committing your changes back to the actual schedule. You can even include planned orders in the snapshot to get a picture of your plants capacity prior to release.

Production Tracking

The Production Tracking application enables a company to report all of its production activity to the shop floor control system. Labor activity, material activity, and management reporting are addressed by Production Tracking, which can be applied to capture work order costs, process or work group efficiency, and production performance reporting. Information collected through this application is used by MRP to keep planning priorities in order and by the work order management application to supply up-to-the-minute information to the production scheduler. Production transactions for labor, material and tools may be generated automatically at standard cost, or collected as actuals or as a combination of both, as required. Manual collection can be turned on for specific areas during a shop tuning process and then turned off again and automatic collection resumed. Labor Reporting provides for the capture of all types of labor used in production: direct, indirect setup, inspection, rework, downtime, machine, tool and more. The job routing defines operations and time required to complete a job. When operations are completed, Labor Reporting is able to report worker and work center efficiency, machine utilization and downtime. W.I.P. Material Moves provides for complete operation-to-operation material tracking. It may be operated in fully automatic mode, or queues can be managed manually or the option may be turned off. W.I.P. Tracking provides various inquiries and reports on work-in-process.

Manufacturing Costing

The Manufacturing Costing tracks actual labor and material costs as they are applied to work orders. Cost adjustments and cost transfers between work orders can be made, as needed, to insure proper postings to the General Ledger. The costing information can be printed on costing reports.

Scrap Material

Scrap Material is used to enter scrap records into the system. Scrap records can be entered into the system in two ways, automatically and manually. Once the scrap records have been entered and committed, they are stored as scrap history.

Labor Reporting

Consisting of labor processing programs and reports, the labor reporting module is used to enter labor transactions as they are reported from the shop floor. These transactions supply data for various applications, such as manufacturing costing and production scheduling. Labor can be reported by crew or individual employee. In addition to manual reporting, operations can be set up to back flush the labor based on the settings in the item's routing. Start/Stop labor entry is provided for real-time data collection on the shop floor. Labor entry writes to the standard labor tables and can be accessed through the standard labor programs. Crew entries are exploded into their member employees for application to the cost of production, so that the rate for each employee can be used for cost calculations. Scrap reporting takes place as part of labor reporting or can be reported separately.

Make to Order Kits

Make to order kits allow for a pre-determined group of items to be sold as a single item number. The kit is assembled during the order picking process. No manufacturing order is necessary to ship a kit. Make to order kits can be sold as either the sum of the components pricing or for a fixed price per kit.