GME Requirements Production Planning and Scheduling

Sr. no Business Process Area User Requirement

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Production Planning Production Planning Production Planning

Masters Masters Masters

Production Planning

Masters

Each raw material item in the inventory, including spares can be identified by a unique identification no. in the materials master. System will be able to track and monitor all item in different pack size using unique identification nos System will support for classification into MRP based materials and NON-MRP based materials. (MRP based materials are sales order specific and procured only on receipt of sales order after considering inventory stocks. NON-MRP based materials are procured based on re-order points. Material Masters can capture the attributes of each raw material item. For e.g. composition, specification , probable vendors, plants where it may be required, whether domestically procured or imported, weather imported against any incentives, excise and customer classification etc. For spares system should capture asset specification, criticality, location, hierarchy, Cost Centre Codes, Asset Codes, Warranty Information, Safety Procedure System will allow auto and manual generation on the requirements based on BOM and sales order. The BOM should be multi-level in nature and also consider inhouse produced finished goods which are used as input for other processes. System will perform an MRP at user defined intervals to consolidate the requirements of raw materials, consumables and packing material across multiple orders and all production lines. During MRP, system will also take into consideration the available Finished good inventory before releasing Purchase requisitions and production orders. System will support a short term (daily) and medium term (few weeks) production plan. System will be able to create a Production Plan to plan for the critical components (raw materials with large lead times, tools, in-house manufactured finished goods) and scheduling of bottleneck work centres. System will support capacity planning across the plants for allocating a production order to a particular production line. Based on the capacity planning, system should also allow transfer of a production order from one production line to the other. System will also support simulation of production schedules for checking tentative date of delivery for expected orders System will support a rough cut capacity planning at work centres to schedule the production orders. System will allow for issue of manual production order and for producing goods to be kept as semi-finished goods. System will allow for edit and store of recipe for production order and should record cost accordingly System will also support the splitting of a job to production lines For scheduling of jobs, system should consider minimum change over time, cleaning time, availability of raw material, line speed, production quantity, etc. and optimize on each of these parameters. System will be able to schedule and prioritize the jobs based on the dispatch date in the sales order. System should be able to group the products based on the parameters of the final product and priority of specified groups should be considered for production. System will also consider any planned maintenance schedules and holidays at the time of scheduling. System will be able to consider any intermediate corrective path in case of quality/ machine failure at any of the work centres. This would result in a new schedule being taken. System will capture QC checklist results at each work centre before production starts on that work centre. The system will allow closing of a production order at each stage of the production and allow on reporting of WIP. Ability to report on past work centre history such as past productivity etc. Report on average lead times across raw materials, manufacturing and Procurement Ability to record customer complaints and support for non conformance reports. Ability to back track upon raw materials based on non-conformance reports. Ability to analyze material usage based on past consumption. Ability to report on Shift wise daily production schedule System will be able to report on the actual production vs. the planned production based on the daily input and schedules generated.

Production Planning

Planning

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Production Planning

Planning

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Planning Planning Planning

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Planning Planning Planning Planning Planning Planning Scheduling Scheduling

Production Planning Production Planning

Scheduling Scheduling

Production Planning Production Planning

Scheduling Scheduling

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Production Production Reports Reports Reports Reports Reports Reports Reports

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GME Requirements Production Planning and Scheduling

Sr. no Business Process Area User Requirement

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Production Planning

Reports

System will be able to give a production summary report, for each job, each day / week / month mentioning the raw material consumption, FG produced etc. System should be able to give a production summary report, for each job, each day / week / month mentioning the raw material consumption, FG produced etc. System will be able to do material planning at product hierarchy ( Bulk Product) System will be able do to material planning as per distribution requirement that requirement raised by Depot / C&F System will be able to support both order based manufacturing as well as stock requirement System will consider material which partially manufactured and unpacked products during material planning

Production Planning

Reports

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GME Requirements Production

Sr. no.

Business Process
Production Planning

Area

User Requirement

Production

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Production

Production

Production Production

Production Production

System will allow issue of raw materials against multiple orders. System should also capture an expected return quantity to be considered during MRP. System should also allow a post facto consumption based allocation of the issued raw material against each of the production orders. System will take into account the conversion between various units of measurement such as KGs, Length, Square meters, Units, Thousands etc and at each stage such as input and output at each work centre. System will do auto-conversion from one user input unit of measurement into other units of measurement System will allow capturing the output quantity and the wastage quantity at each work centre.

Production

Production

9 11 12 13

Production Production Production Production

Production Production Production Production

System will be able to identify each material on the shop floor as WIP, using unique identification codes. These codes should capture: Type of Items- such as RM, WIP, Waste Item etc. Item - The actual material produced items like crab stick, etc. Semi-Finished Goods stock will be tracked using these WIP codes for quantity as well as value. System will also have the ability to track and record the transaction the Raw materials, packing and Finished goods using bar codes. System will also compute the idle time for each work centre based on the captured production data. System will be able to capture and report on shop floor data consolidated on date, machine, shift, process and job. Data to be captured are input / output quantities, consumption of materials, units of measurement, start and end time of the process, idle time, setup time for eac SKU, labour time, machine time etc. System will be able to calculate the machine efficiency based on standard and actual parameters such as speed, run time etc. As the actual consumption for materials, labour and machine hours can be different from standard consumption - system will allow for variance monitoring and analysis MIS on productivity such as total input and output of materials and reporting per work centre wise, plant wise etc. Ability to report on the cost of production for each finished and semi-finished good. System will be able to interface with plant automation systems (Weighing M/c.) System will able to store production job history such as cause of variance , notes System will be able to support creation of alterative Bill of materials for product

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