ERP• Single window solution of enterprise where in each and every sections / departments and locations are integrated in to one.• Information flows from one place to another automatically with no repetition of entry.• Based on ISO guidelines therefore it automates business process in a more systematic way and help enterprise to achieve various level of standards in quality.
PRODUCTION Module• Designed for specific needs of manufacture industries include core capabilities.• Facilitates production planning , Taking orders and delivering products to customers.
Production Module Features• Process definition with inputs, outputs, by-products and overheads• Definition of Bill of Material(BOM) for all products up to any number of levels• Planning based on customer wise production advice and sales forecast• Material requirement planning: MRP based on machine capacity and availability, machine efficiency, raw material availability, lead time - giving feasible quantity for production.• Production plan for machines with optimum utilization of all available resources like raw materials and machines
Production Module Features (Contd..)• Production plan for machines with optimum utilization of all available resources like raw materials and machines• Option to revoke production plan to change input parameters/ production priority/ quantity using fresh production advice• Generation of production schedule for machines detailing inputs and output• Reserving quantity for production• Automatic generation of job orders for production• Option to make daily plans for production 6
The sub modules of Production• Production Control• Requirements Planning• Capacity Planning• Preventative Maintenance• Structures and Routings• Cost Control• Time and Attendance• Quality Control• Job Costing• Service and Repair• Engineering Project Management
Characteristics of Production Module• Production Planning helps an organization plan production with the optimum utilization of all available resources.• Material Requirement Planning is done based on the production advice generated by the sales department.• Feasibility of production is evaluated using details like raw material availability and procurement time, machine availability and capacity.• A production schedule is generated for all machines where the scheduling is done in an optimized fashion based on the priorities of production.
SAP Modules SD – Sales and Distribution FI – Financial Accounting MM – Materials SD FI CO – Controlling Management MM CO PP – Production Planning AM – Asset Management PP AM QM SAP R/3 HRQM – Quality Management PM WF HR – Human Resources PM – Plant Maintenance WM PS WF – Workflow WM – Warehouse PS – Project System Management
Production Planning Module• To plan and control the manufacturing activities• Key elements • Bill of Material (BOM) • Routings • Work Centers • Sales and Operations planning (SOP) • Master Production Scheduling (MPS) – Capacity Planning • Materials Requirement Planning (MRP) • Shop Floor Control (SFC) • Production orders • Product costing, activity-based costing • Work in process • Kanban • Production planning for process industries (PP-PI) • Repetitive Manufacturing
SAP-Production Planning SD PP PS SD •Sales and Operations Project Planning Networks Customers SD •Demand management PM SD Sales •MRP Maintenance Shipping •Detailed Scheduling & Repairs Billing Planning Plant •Capacity planning maintenance Vendors Purchasing MMSD •Shop floor control QM SD Warehouse •Costing Inbound Raw Invoice •Information system Material verification Finished GoodsFI CO HR Financial Cost Human accounting accounting resources
Visual GEMS -Production Management• Production planning – Defining Factory Capacity based on Standard (Basic) style. – Allocating Orders to factories based on criteria such as no of machines, daily output or production span. – Graphical Order Allocation Chart for monitoring allocations.• Generation of Production Orders• Tracking of Orders. 19
Visual GEMS -INPUT DATA• Production Order Job Work Order requisitions• Periodic Production Monitoring Reports• Job Work reconciliation report from job worker• Processing Order requisition (rough processing Order) 20
Visual GEMS-OUTPUT DATADocuments Reports• Production Orders • Production Order Status• Processing Orders – Order Wise – Operation Wise• Cutting Requisition – Monitoring Monthly• Trim requisition • Order Register • Order Follow Up • Issue Consolidation Report - Cutting / Trims 21
STARTPRODUCTIONMANAGEMENT MODULE IE GIVES THE PRODUCTION PLAN Production Manager reviews the Production Plan Production Department receives INVENTORY materials from the Inventory DEPARTMENT Patterns from Pattern SPREADING Making Department CUTTING CONTINUED 22
CONTINUED NO Cut Pieces instantly moved Kept for Inventory WIP to Sewing Line YESCut Pieces Transported to Assembly Line Line Balancing Assembly Line Inspection CONTINUED 23
CONTINUED NO NO Reject the Matches with Defect can be Fixed modified? Piece Standard? YES YES MODIFICATIONFinal output sent to Finishing Department END 24
Click on the above Module Names to see screen forms) Export Orders Inventory ProductionExport Order Entry Accessory Stock Production PlanningStyle Data Bank/Dispatch Fabric Stock Production OrdersFabric Working Yarn Stock Processing OrdersYarn Working Garments Stock Production MonitoringSample Approval Opening Stock Production ReconciliationMeasurement ChartsCosting Template Gate Pass Import Monitoring DataEO Closure / Locking Issue Control Centre Order Closure Purchase Orders Import Export DocumentationPurchase Order For Import L/C Export LC# Fabric Import Bill entry Quota# Accessory Export Incentives (DBK)# Yarn Import L/C Register Pre-shipment Invoice Packing List# Garment Back To Back L/C Commercial Invoice PO Without L/C Import Bill tracking Draft / Bill of exchangeOrder Closure Bank certificate 25
APPS PRODUCTION PLANING & CONTROL MODULE• Production Process Planning• Production PO Generation• Lot Cut Plan Creation• Daily Cutting Tracking• Production Issue & Received Follow up• Finished Goods Received Tracking• WIP Transfer• Daily Production Report Generation• Production Summary Generation• Vendor Payment Tally Sheet Generation 32
APPS 8i -Features• Efficiency Planning• Unit Resource Planning• Machine Planning• Target Setting• Master Plan generation• Production Plan Report• Machine Allocation status• Daily Plan details• Order Plan details• Planned Vs. Actual 33
PROMAN 3.0• PROMAN is a production management software which monitors all activities on the shop floor from time study and production planning till the garment is finished and packed. It smoothly integrates all the operations in a garment factory and generates very useful MIS reports to remove bottlenecks and improve productivity. This can also seamlessly integrate with STAGE or work independently. PROMAN improves profitability, reduces production costs, improves product quality. 36
PROMAN 3.0• PROAMN identifies bottlenecks in the Production Line and alerts the line supervisor so that the problem can be addressed and production in the line can be balanced.• Work In Progress at each location can be generated• Option to plan capacities with learning curves. Automatic MIS Report Generation can save a lot of time for users by avoiding manual / spreadsheet reports.• PROMAN also has the option to track daily production using bundles tickets with barcode. 37
REPORTS• Factory Production Report• Bottleneck Report• WIP Report• Machine Deployment Analysis• PPDPM Report (Graph and Data)• Day wise Factory Summary• Bundle Tracking Report• Production Summary Department wise• Daily Production Summary Factory wise• Line wise daily Production ReportDaily• Finishing ReportSkill Assessment Report• Daily Cutting Report• Incentive Statement Report 38
PROMAN 3.0• P.O. Status Report• Piece Rate Report• Factory Efficiency Report• End batch, Finishing & AQL Reports• Employee Efficiency Range Report• Finishing & Packing Reports• End bit Stock Report• Machine and Spare Parts Inventory Reports 39
PRODUCTION PLANNING• Product structure, dependent relationships and ECO functions are all fully integrated with scheduling, manufacturing routings, capacity planning and MRP. PRO:MAN delivers maximum visibility into inventory and capacity requirements.• Bills of Material• Master Scheduling• Material Requirements Planning• Capacity Planning and Routing 40