Manufacturing and Production

Planning Module
It provides solution to the production and
planning functions of an organisation to
efficiently maintain share and utilise the data
generated during the processes and assist the
management
Manufacturing applications must allow an
easier exchange of information throughout the
entire global enterprise, or at a single site
within a company.
The manufacturing system must be integrated
with the other modules of the package

 Regardless of how manufacturers view

their internal operations, to the customer,
it boils down to quick response to
customer demand in two fundamental
ways.
Manufacturers either make products to
stock, prior to receipt of a customer order,
or they make and ship the products upon
receipt of a customer order.
Manufacturers must accomplish this task
quickly, efficiently, and cost effectively to
remain profitable and competitive

 Manufacturers must respond quickly

and effectively to customer demands
while agility is desirable.
Since, agility without an effective
enterprise manufacturing system
results in speed without purpose.
The very heart of an enterprise
manufacturing system centres on its
integrated
planning,
business
process and execution capabilities

 Strategically, effective planning results in

improved
inventory
turns,
increased
productivity, and improved ROA.
Tactically, effective business processes provide
improved customer satisfaction, reduced time
to market, and improved market share.
Effective execution provides short cycle time,
quality assurance, continuous improvement,
and quick response to process variability.
All three elements contribute to management's
decision
to
install
an
enterprise-wide
manufacturing management system.

Subsystems of Manufacturing module

Material and Capacity Planning

Shop Floor Control
Quality Management
JIT/Repetitive Manufacturing
Cost Management
Engineering Data Management
Engineering Change Control
Configuration Management
Serialisation / Lot Control
Tooling

Material and Capacity

Planning

Customers want accurate shipment dates,

sometime to the hour, even when there are
schedule and product changes.
The Planning systems of ERP packages are
designed to provide the responsiveness your
company needs to meet those customer
requirements.
With these systems, the management can
simulate alternative plans; gaining the information
they need to determine which parts and
assemblies to make, which to buy, and when to
manufacture or purchase.

 For analysis, planners can create an

unlimited number of simulations
Graphical reporting makes potential
material and capacity problems easy to
identify.
The ERP packages give your company full
control with flexible scheduling, and
sophisticated shop floor functionality.
Depending on the requirements of the
company's
product
and
processes,
production can be scheduled using work
orders

Shop Floor Control

Process reengineering efforts and the elimination
of waste are greatly dependent upon powerful,
user-friendly and flexible shop floor planning, and
control over this system
Factories are being realigned to reduce material
travel time through a facility, adding burden upon
the supporting systems due to realignment of
places.
Managers must often experiment with trial and
error approach, the never-ending search for
process improvement.
Shop floor control systems must be flexible and
adaptable to changing needs.

 A shop order can be reprinted at any time with user

selection of whether to reallocate material.
This reprinting gives a shop foreman flexibility to print a
duplicate copy when an order is split between operators.
This feature also gives the shop scheduler, the ability to
reprint the shop packet and to reflect new material
allocations that correct previous shortages.
Shop order maintenance capability of ERP systems
allows the user to evaluate and adjust operation steps
and components.
Orders can be rescheduled either backward or forward.
For example, an operation's start date can be overridden
to reflect changed events and then, the order can be
forward scheduled to reflect the impact upon future
operations.

Quality Management
All manufacturing modules track quality
control activities across the enterprise,
from intermediate producers to finished
goods.
These systems allow a wide variety of
characteristics and parameters to be
specified
in
test
and
inspection
operations.
They also maintain an extensive history of
data, to improve product quality and
identify recurring problems

 Material Inspection subsystem offers a

wide range of capabilities for process
supervision and control.
These capabilities are fully integrated with
the other modules like purchasing,
inventory management, and shop floor
control functions, to ensure that the right
quality control procedures are followed
Material Disposition is another feature
available in many systems.
It offers advanced disposition functions
and material review that ensure the right
quality control decisions are made.
It must also provide an audit trail of

JIT/Repetitive Manufacturing
Many companies have embraced the concepts of
waste
elimination,
product
factory
layout,
manufacturing cells, and Kanban signalling.
But, many implementations have struggled due to
lack of software tools to effectively support the
transition.
Many systems, not only provide high volume
repetitive manufacturing functionality, but also
provide for the transition to rate-based production.
This allows the use of repetitive scheduling, even for
products that are not based on rate.
This allows a production facility to, shift products from
discrete manufacture into a JIT/ Repetitive focus.

 The capability for transition enables production

facilities to adopt process reengineering, setup
reduction programs, single minute exchange of
die programs, employee empowerment work
teams, and so on.
A JIT work list compares the production plan to
the capacity plan for rate-based items.
This tool quickly identifies discrepancies based
upon actual performance, so that production
rates and/or daily output goals can be
adjusted proactively and monitored on a
timely basis.
Reports covering employee efficiency and
detailed cost by item are also provided

Cost Management
A
business
needs
accurate
and
detailed
manufacturing cost reporting for effective business
management.
ERP packages provide extensive cost information at
several levels
They
support
multiple
inventory
valuation
methods, so that you can choose the costing
method that best reflects your company's business
To reduce administrative overhead, prevent input
errors, and provide faster and more accurate
information for planning, these systems provide
detailed records of time and materials data on the
shop floor.
Many systems have features that let your company
compare, estimates and production costs for

 The systems can track material usage

for each job.
And, if the activity is associated with
a project, project information is
automatically updated.
There will be provisions that allow
employees to report non production
activities such as maintenance,
holidays, and illnesses.
Manufacturing
system
provides
extensive
information
about
production costs at several levels that

Engineering Data Management

The first step to shorter product development

cycles is increased efficiency in design and
development activities.
Engineering Data Management is designed to
help an organisation to trim data transfer
time, reduce errors, and increase design
productivity.
The Engineering Data Management achieves
this by providing an automated link, between
engineering and production information.
Most packages allow a smooth integration,
with popular Computer Aided Design (CAD)
packages, to simplify the exchange of
information about drawings, items, Bill of

Engineering Change Control

By using Engineering Change Control,
businesses can gain effective control
over engineering change orders.
Company can define the authorisation
steps for approving and implementing
an Engineering Change Order.
When these steps are completed, the
system automatically implements the
change in the production database.

Configuration Management
The
Configuration
Management
dramatically reduces order cycle time.
This is achieved by eliminating the lengthy
engineering review, typically associated
with determining feasibility and the costs
associated with the configured end item.
This reduction is achieved by, creating a
flexible user-defined knowledge base that is
accessed by a powerful analytic engine.

 The knowledge base contains the sales and

engineering expertise of the organisation.
Product attributes and variables, such as height,
width, or cubic pounds of pressure, are entered
in the knowledge base in the form of an option
matrix.
The analytic engine interprets the knowledge
base, in conjunction with user selections, to
ensure that the customer-specified product can
be built and sold.
As a result, the order entry process is a dynamic
conversation between the order taker and the
customer, who culminates with a fully priced
product on the sales order.

Serialisation/Lot Control
Many systems will provide the facility for the designation of
raw material lots and the serialisation of component parts
made from those lots.
This serialisation is applicable to commercial aviation,
defence industry suppliers, and capital equipment
manufacturers, who provide service over the life of their
products on an individual unit by unit basis.
Manufacturers, who use lot control often, must allocate
production prior to its completion.
The lot control system provides for the pre-allocation of lot
numbers.
This feature is available throughout the product offering
and includes MRP, shop floor control, order processing, and
JIT.
Many systems allow production orders to be pre-assigned
with lot numbers for the parent item.

Tooling
For many manufacturers, ensuring that
proper tooling is available is very critical to
production schedules.
The ERP system extends capacity and
inventory management to include these
valuable resources.
These systems help to ensure that tools and
materials are together at scheduled
operations, by storing tools in inventory,
planning, and allocating the required tools
as part of the production order.
They always provide visibility of tool use.
Calculate the remaining useful life of a tool