ERPAreasandModules/Manufacturing

Themodulesallowtightcontroloverproductionorders,shopfloorandcapacityplanning,billsofmaterial,lotcontrolling,costingand
stockmanagement.ForcustomedproductionasophisticatedProductBuildermoduleisavailableintegratedwithcomponentsand
processes.
OrderHandling

1.1.OrderType
Anunlimitednumberoffunction
flowscanbecreatedtodefine
ordertypes.
Productionorderscanbedefined
tomakeaonelevelbreakdown
oradrilldownbreakdownof
components.
Individualplanningofcomponent
productionisavailableatmixed
levels.
Anunlimitednumberof
unreleasedproductionorderscan
becreatedtoallowforlimitless
flexibilityinplanning.Unreleased
productionorderscanbe
releasedasworkingproduction
ordersatanytime.

1.2.RelatedCustomerOrder
Customerorderscanbelinkedto
productionordersallowing
automaticupdatingofthe
confirmationandcompletion
datesoncustomerordersincase
ofreplanning.
Customerorderscandirectly
createproductionordersfor
directplanningandconfiguration.

1.3.ReleaseOrder
Productionorderscanbe
withheld,causingstock
reservationstobemadebutnot
permittingtimeandmaterial
reporting.
Whentheproductionorderis
released,theconfirmationdate
ontherelatedcustomerorder
willbesetautomatically,andthe
deliverydatewillbesetto
includeaqualitycontrolphase.

1.4.BillofMaterials/Different
Versions
Itispossibletocreatean
unlimitednumberofbillsof
materials,suchasproduction,
sales,planning,andnot
approved.
Thisallowscompleteflexibilityin
thedesignandplanningphases.
ItallowsanIntegratedCAD
systemtogenerateabillof
materialsinthedesignphase.
1.5.BillofMaterials/Kits
Anunlimitednumberof
?phantom?itemsarepermitted.
Thebreakdownofphantomitems
isautomaticallyperformed.

1.6.BatchControlandSerial
Numbers
Batchcontrolallowstracingof
batchesfromthearrivalof
purchaseitemstocustomer
delivery.
Eachitemcanbeassigneda
uniqueserialnumberthatcanbe
tracedthroughtheproduction
processallthewaytocustomer
delivery.
1.7.StartingandEndingDates
Capacityplanningallowsforward
andbackwardcapacityplanning
inrelationtothestartingor
endingdate,bothconstrained
andnonconstrained.
1.8.PrintProductionOrder
Afullarrayofprinteddocuments
includingproductionorders,job
cards,productionorderoverview
withprices,subvendorsetc.,are
available.

1.9.OnlineMaterialandTime
Tracking
Eachtimeandmaterialreportis
immediatelyavailableonlinein
realtime.
Userscanseeifthepre
calculatedpriceisaccurateatany
pointintheproductionprocess.
1.10.MaterialIssue
Materialcanbeissuedina
varietyofways?
Automatically,withapickinglist
onadaytodaybasisorbasedon
anyintervalofdates.
Manually,componentby
component.
Automatically,backflushrelated
toreportingofproduction
completion.

1.11.OrderReceiving
OrderReceivingcanbebookedin
avarietyofways?
Automatically,onadaytoday
basisorbasedonanyintervalof
dates.
Manually,componentby
component.
Partiallyorcompletely.

1.12.SubContractors
Operationscanbedefinedasin
houseoroutofhouse.
Subcontractorsbecomepartof
theoperationalplan,setupin
SoftBASEBase.
Pricingperoperationandsub
vendorbasedondatesand
quantities.
Subvendorqualitycontrol.
Anautomaticoverviewof
shippingandreceivingdatesis
providedtoassureontime
deliverytoandfromsub
contractors.
Issueofgoodstothesubvendor
withdeliverynote.
Receiptofgoodsfromsubvendor
withqualitycontrol.
Subvendorinvoicevertification
againstsubvendororders.
Overviewofwhereareyour
goods.

1.13.Backflush
Componentdeliveriesaremade
aftereachproductionreport,
allowingmaximumstockcontrol.
Itisnotnecessarytocreatea
pickinglistbeforeproduction
begins.

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MRPFunctions

2.1.Versions
Allowsanunlimitednumberof
versionsofamaterial
requirementplan.
Materialrequirementplanscan
becreatedperplant,per
productiongroup,perplanner,or
perwarehouse.
2.2.FilteringParameters
Filteringparameterseliminate
theneedforthematerial
requirementplantoreactto
everyplanningchangebysetting
thetolerancetochange.
2.3.DaysofUsage
Thematerialrequirementplan
canbecalculatedaccordingtoan
intervalofdayssetbythe
customer.

2.4.FixedOrderSize
Thematerialrequirementplan
canbecalculatedforafixed
ordersize.
Overproductionisautomatically
allocatedtothenextproduction
phase.
2.5.LotforLot
Specialorderingofsensitive
materialispossible.
2.6.SafetyStock(Minimum
Inventory)
Aminimuminventorythatactsas
safetyreservestockcanbeused
asthebasisforcalculation.

2.7.NetRequirementCalculation
Thedifferencebetweenactual
materialinstockand
requirements,purchaseorders,
andproductionordersis
calculated.
Suggestsachangetoproduction
orders.
Suggestsachangetopurchase
orders.
2.8.GrossRequirementCalculation
Calculatesrequirementsbasedon
stockandrequirements.
2.9.ByFactory
Materialrequirementplanscan
becalculatedperfactory.

2.10.ByWarehouse
Materialrequirementplanscan
becalculatedperwarehouse.
2.11.SalesPrognosis
Canmakeamaterialrequirement
planbasedonthesales
prognoses.
2.12.Pegging
Adrilldownfacilityallowsusers
toseetheoriginsofeach
materialrequirementplan
suggestion.

2.13.Simulations
Allowsanunlimitednumberof
materialrequirementplan
simulations.
2.14.PurchaseProposal
Createsproposalsforpurchase
items.

2.15.ProductionProposal
Createsproposalsforproduction
items.
2.16.DeviationStatistics
Createsstatisticsbasedonthe
deviationbetweenplannedand
actualproductionandpurchase
requirements.

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Costing

3.1.PrecalculationItemCostingor
OrderCostin
Precalculationisperformed
usingabottomupsummaryof
materialcoststhroughthebillof
materials.Abottomupsummary
ofproductioncostscanbe
dividedintomanhourcostsand
machinecostswhichcanbe
furtherdividedintosetupcosts
andproductioncosts.
Calculatesaddonssuchas
commission,freight,customs,
tax,etc.
Calculatesyield.
Canbeperformedonthebasisof
standardcost,latestcost,or
averagecost.
Calculatessubvendorcosts.
Isbasedontheactualentered
hoursandmaterials(order
costing)

3.2.OnlineCalculations
Followseachproductionorderby
timereportingandmaterial
reporting.
Comparestheactualcostofa
productionorderwithplanned
costs.
3.3.Simulations
Allcostcalculationscanbedone
inversionsallowingforcomplete
planningbasedonstandardcost,
latestcost,oraveragecostand
includingunlimited?whatif?
situations.

3.4.PriceListUpdating
Basedonthecalculationofcost
rollup,itautomaticallyupdates
thesellingpricelist.
Allowscalculationofcostprice
plusacontributionbymargin.
3.5.StockRevaluation
Inhousestockwillberevaluated
basedonthenewstandardcost.
3.6.StandardCost
Updatedautomaticallyfromthe
purchaseandmanufacturing
modules.
Updatedonanitemlevel,an
itemstocklevel,andastocklevel.

3.7.LatestCost
Updatedautomaticallyfromthe
purchaseandmanufacturing
modules.
Updatedonanitemlevel,an
itemstocklevel,andastocklevel.

3.8.AverageCost
Updatedautomaticallyfromthe
purchaseandmanufacturing
modules.
Updatedonanitemlevel,an
itemstocklevel,andastocklevel.

3.9.NetCostIncludingCustoms,
ShippingCosts,Etc.
Calculationofnetcostfromthe
purchasemoduleincludescosts
relatedtoitemsbeforetheyare
inyourstockandaftertheyhave
beenaddedtoyourstock
includingfreightcosts,customs,
etc.

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CapacityPlanning

4.1.Groups
Groupsaretheorganizationof
yourworkcenters.
Userscanviewtheoverall
capacityofthegroup.
Userscanplanoperationsfor
eachgroup.
4.2.WorkCenters
Workcenterscanbeorganized
accordingtogroups.
Userscanviewtheoverall
capacityoftheworkcenter.
Userscanplanoperationsfor
eachworkcenter.

4.3.Calendar
Thecapacitycalendarcanbe
attachedtogroupsandwork
centers.
Planningcanbedoneinonehour
increments,sevendaysaweek.
Eachhourofeachdaycanbe
definedindividually.
4.4.ForwardScheduling
(Constraint/NoConstraint)
Planningisdonebasedonthe
productionstartingdateusing
eitherconstraintornoconstraint.
Calculatestheearliestpossible
startingdateandthencalculates
anendingdate.
Recalculatesthelatestpossible
startingdatebasedontheending
date.

4.5.BackwardScheduling
(Constraint/NoConstraint)
Planningisdonebasedonthe
productionendingdateusing
eitherconstraintornoconstraint.
Calculatestheearliestpossible
startingdatebasedontheending
date.
4.6.GraphicOverviewofCapacity
Usage
Showscapacityusageonaday
todaybasisforthegroupand
theworkingcenters.
Showsundercapacity,full
capacity,andovercapacity.
Zoominallowsviewingof
individualproductionorders.

4.7.OrderGanttChart
Givesanoverviewofgroupsand
theworkingcentersby
productionorder,operation,or
dates.
4.8.TimeReporting
Timecanbereportedby
operationonindividualwork
center.
Providesoverviewoftimeusage
andofcompletionoftheorderby
quantities.
4.9.TimeUsageStatistics
Providesaverageusagebygroup,
workcenter,day,month,and
order.
Providesanoverviewofthe
currentprogressofanorder
accordingtoplannedtime.
Allowsforoptimalplanningand
analysisofworkerproductivity.

4.10.OverlappingOperations
Allowsforplanningof
overlappingoperations.
Canbedefinedbytimeor
quantityofcompletionof
currentlyrunningoperation.
Canbedefinedinabsolutetime
andquantitycompletedor
relativetimeandquantity
completed(percent).
4.11.ParallelOperations
Allowsforplanningof
overlappingoperations.

4.12.Yield
Automaticallycalculatesspoilage.
Calculatestimeandmaterial
(materialrequiredinandmaterial
requiredout).
Automaticallycalculatescost.
Allowsforreuseofspoiled
materialwhileupdatingtime
usage.
4.13.EfficiencyPercentage
Allowscalculationofactually
efficientworktime.
Manpowerfactor.
Machinehoursfactor.
Inbothsetupandproduction
phases.

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Forecast/MainPlanning

5.1.ProductionForecast
Consolidationscanbemadefrom
allsalesforecasts.
Anunlimitednumberofversions
arepossible.
Canbemadeformultipleyears
simultaneously.
5.2.ByItem
ASalesPrognosisConsolidation
canbemadeperitem.
5.3.BySalesGroup
ASalesPrognosisConsolidation
canbemadepersalesgroup.
5.4.ByDistrict
ASalesPrognosisConsolidation
canbemadeperdistrict.

5.5.Simulations
Itispossibletorunsimulated
SalesPrognosisConsolidations.
5.6.Averaging
Totalproductionrequirementsin
aperiodcanbedeliveredovera
fiveweekperiod.Averagescan
bechangedmanually.
5.7.Overview
Theoverviewshowsproduction
requirementsbyday,byweek,
andbymonth.
Peggingfunctionshowsindividual
originsofeachproduction
requirement.

5.8.ForecastConsolidation
ConsolidatesSalesPrognosis
ConsolidationsintoaMaster
ProductionPlan.
5.9.ProductionTotalofUnitsper
Factory,perTimeUnit
MasterProductionPlansaresub
dividedperfactoryandpertime
unit.
5.10.Versions
Createspreliminaryversionthat
canbechangedmanually.
Createsadefinitiveversionthatis
locked.
Allowsanunlimitednumberof
definitiveversions.
Worksaccordingtoitempolicy.
5.11.Simulations
Allowsunlimitednumberof
masterplansimulations.

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ProductBuilder

6.1.SalesConfiguration
Unlimitedparametersinorderto
determinethesoldproduct.
Completeprice/costcalculation
ofthesoldproduct.
Automaticpromptingfor
parametersandvariablesforthe
salesorder.
Predefinedvariablesforthesales
order.
Billofmaterialselectionson
unlimitedlevels.
Automaticselectionofoptions
andfeaturesbasedoncalculated
formulas.
o Minimumandmaximum
valuesrangeofformulas.
o Resultinginautomatedif
thenelseselections.

6.2.ProductionConfiguration
Detailedparametersinorderto
determinethefinalBOMforthe
configuration.
Finalcostofproductswith
featuresisautomatically
calculatedintheprecalculation
oftheproductionorder.
Predefinedvariablesfor
production.
Billofmaterialselectionson
unlimitedlevels.
Automaticselectionofoption
andfeaturesbasedoncalculated
formulas.
o Minimumandmaximum
valuesrangeofformulas.
o Resultinginautomatedif
thenelseselections.

6.3.ConfigurationFormulas
Configurationprofilewithoneor
moreformulas.
Itispossibletoenter
configurationformulasusing
correctmathematicalsymbols
andexpressionsincluding
variables.
Configurationprofileattachedto
oneormoreitems.
Predefinitionofvariablesper
item.
Variablesindialogue.
Formulasattachedtooneor
morebillofmaterialnodes.
Anadvancedproduct
configuratorisusedtocalculate
componentsandmaterialneeds
accordingtothedynamic
configurationoftheproducts.

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6.4.BillofMaterials
Billofmaterialscanbecalculated
asaresultofformulasand
dialogueboxes.
Automatedselection/de
selectionofcomponents
accordingtominimumand
maximumvalues.
Billofmaterialconfigurationin
flexiblelevelsforsaleand
production.
Billofmaterialversions.
Start/enddatevalidityperbillof
materialnode.

6.5.BillofMaterials/Options
Optionscanbecalculatedasa
resultofformulas.
Optionscanbeautomatically
selectedasaresultofformulas
anddialogueboxes.
Optionscanbemanuallyselected
andgivenotherselection
possibilitiesonlowerlevels
Finalcostofproductswith
featuresisautomatically
calculatedintheprecalculation
oftheproductionorder.

6.6.BillofMaterials/Features
Featurescanbecalculatedasa
resultofformulas.
Featurescanbeautomatically
selectedasaresultofformulas
anddialogueboxes.
Featurescanbemanually
selected,givenotherselection
possibilitiesonlowerlevels.
Finalcostofproductswith
featuresisautomatically
calculatedintheprecalculation
oftheproductionorder.

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