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Production module


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Production module

  1. 1. ERP-Production Module
  2. 2. ERP <ul><li>Single window solution of enterprise where in each and every sections / departments and locations are integrated in to one. </li></ul><ul><li>Information flows from one place to another automatically with no repetition of entry. </li></ul><ul><li>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. </li></ul>
  3. 3. Integrated solution
  4. 4. PRODUCTION Module <ul><li>Designed for specific needs of manufacture industries include core capabilities. </li></ul><ul><li>Facilitates production planning , Taking orders and delivering products to customers. </li></ul>
  5. 5. Production Module Features <ul><li>Process definition with inputs, outputs, by-products and overheads </li></ul><ul><li>Definition of Bill of Material(BOM) for all products up to any number of levels </li></ul><ul><li>Planning based on customer wise production advice and sales forecast </li></ul><ul><li>Material requirement planning : MRP based on machine capacity and availability, machine efficiency, raw material availability, lead time - giving feasible quantity for production. </li></ul><ul><li>Production plan for machines with optimum utilization of all available resources like raw materials and machines </li></ul>
  6. 6. Production Module Features (Contd..) <ul><li>Production plan for machines with optimum utilization of all available resources like raw materials and machines </li></ul><ul><li>Option to revoke production plan to change input parameters/ production priority/ quantity using fresh production advice </li></ul><ul><li>Generation of production schedule for machines detailing inputs and output </li></ul><ul><li>Reserving quantity for production </li></ul><ul><li>Automatic generation of job orders for production </li></ul><ul><li>Option to make daily plans for production </li></ul>
  7. 7. The sub modules of Production <ul><li>Production Control </li></ul><ul><li>Requirements Planning </li></ul><ul><li>Capacity Planning </li></ul><ul><li>Preventative Maintenance </li></ul><ul><li>Structures and Routings </li></ul><ul><li>Cost Control </li></ul><ul><li>Time and Attendance </li></ul><ul><li>Quality Control </li></ul><ul><li>Job Costing </li></ul><ul><li>Service and Repair </li></ul><ul><li>Engineering Project Management </li></ul>
  8. 8. Characteristics of Production Module <ul><li>Production Planning helps an organization plan production with the optimum utilization of all available resources. </li></ul><ul><li>Material Requirement Planning is done based on the production advice generated by the sales department. </li></ul><ul><li>Feasibility of production is evaluated using details like raw material availability and procurement time, machine availability and capacity. </li></ul><ul><li>A production schedule is generated for all machines where the scheduling is done in an optimized fashion based on the priorities of production.  </li></ul>
  9. 9. P L A N N I N G M O D U L E
  10. 11. Case Study of Production Module <ul><li>SAP </li></ul><ul><li>Visual GEMS </li></ul><ul><li>APPS </li></ul>
  11. 12. Production planning module
  12. 13. SAP Modules SAP R/3 FI WF PS PM WM PP MM SD HR AM CO QM PP – Production Planning WM – Warehouse Management PM – Plant Maintenance AM – Asset Management PS – Project System MM – Materials Management SD – Sales and Distribution QM – Quality Management WF – Workflow HR – Human Resources CO – Controlling FI – Financial Accounting
  13. 15. <ul><li>To plan and control the manufacturing activities </li></ul><ul><li>Key elements </li></ul><ul><ul><li>Bill of Material (BOM) </li></ul></ul><ul><ul><li>Routings </li></ul></ul><ul><ul><li>Work Centers </li></ul></ul><ul><ul><li>Sales and Operations planning (SOP) </li></ul></ul><ul><ul><li>Master Production Scheduling (MPS) – Capacity Planning </li></ul></ul><ul><ul><li>Materials Requirement Planning (MRP) </li></ul></ul><ul><ul><li>Shop Floor Control (SFC) </li></ul></ul><ul><ul><li>Production orders </li></ul></ul><ul><ul><li>Product costing, activity-based costing </li></ul></ul><ul><ul><li>Work in process </li></ul></ul><ul><ul><li>Kanban </li></ul></ul><ul><ul><li>Production planning for process industries (PP-PI) </li></ul></ul><ul><ul><li>Repetitive Manufacturing </li></ul></ul>Production Planning Module
  14. 16. SAP-Production Planning FI CO HR Cost accounting Financial accounting Human resources Project Networks Maintenance Repairs Plant maintenance Inbound Raw Material Finished Goods <ul><li>Sales and Operations Planning </li></ul><ul><li>Demand management </li></ul><ul><li>MRP </li></ul><ul><li>Detailed Scheduling & Planning </li></ul><ul><li>Capacity planning </li></ul><ul><li>Shop floor control </li></ul><ul><li>Costing </li></ul><ul><li>Information system </li></ul>Purchasing Warehouse Invoice verification Sales Shipping Billing Customers Vendors SD PP SD SD SD MM SD QM SD PM SD PS
  15. 18. Visual GEMS
  16. 19. Visual GEMS - Production Management <ul><li>Production planning </li></ul><ul><ul><li>Defining Factory Capacity based on Standard (Basic) style. </li></ul></ul><ul><ul><li>Allocating Orders to factories based on criteria such as no of machines, daily output or production span. </li></ul></ul><ul><ul><li>Graphical Order Allocation Chart for monitoring allocations. </li></ul></ul><ul><li>Generation of Production Orders </li></ul><ul><li>Tracking of Orders. </li></ul>
  17. 20. Visual GEMS - INPUT DATA <ul><li>Production Order Job Work Order requisitions </li></ul><ul><li>Periodic Production Monitoring Reports </li></ul><ul><li>Job Work reconciliation report from job worker </li></ul><ul><li>Processing Order requisition (rough processing Order) </li></ul>
  18. 21. Visual GEMS-OUTPUT DATA <ul><li>Documents </li></ul><ul><li>Production Orders </li></ul><ul><li>Processing Orders </li></ul><ul><li>Cutting Requisition </li></ul><ul><li>Trim requisition </li></ul><ul><li>Reports </li></ul><ul><li>Production Order Status </li></ul><ul><ul><li>Order Wise </li></ul></ul><ul><ul><li>Operation Wise </li></ul></ul><ul><ul><li>Monitoring Monthly </li></ul></ul><ul><li>Order Register </li></ul><ul><li>Order Follow Up </li></ul><ul><li>Issue Consolidation Report - Cutting / Trims </li></ul>
  19. 22. CONTINUED PRODUCTION MANAGEMENT MODULE START IE GIVES THE PRODUCTION PLAN Production Manager reviews the Production Plan Production Department receives materials from the Inventory INVENTORY DEPARTMENT SPREADING CUTTING Patterns from Pattern Making Department
  20. 23. CONTINUED CONTINUED Cut Pieces instantly moved to Sewing Line Cut Pieces Transported to Assembly Line Line Balancing Assembly Line I nspection Kept for Inventory WIP YES NO
  21. 24. CONTINUED Matches with Fixed Standard? Final output sent to Finishing Department MODIFICATION END Defect can be modified? Reject the Piece YES YES NO NO
  22. 25. Click on the above Module Names to see screen forms)  Export Orders Purchase Orders Production Export Documentation Import Inventory Export Order Entry Style Data Bank/Dispatch Fabric Working Yarn Working Sample Approval  Measurement Charts Costing Template EO Closure / Locking Accessory Stock Fabric Stock Yarn Stock Garments Stock Opening Stock Gate Pass Issue Control Centre Production Planning Production Orders Processing Orders Production Monitoring Production Reconciliation Import Monitoring Data Order Closure Purchase Order For  #  Fabric #  Accessory #  Yarn #  Garment Order Closure Import L/C Import Bill entry Import L/C Register Back To Back L/C PO Without L/C   Import Bill tracking Export LC Quota Export Incentives (DBK) Pre-shipment Invoice Packing List Commercial Invoice Draft / Bill of exchange Bank certificate  
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  25. 28. APPS 8i ERP (Apparel-specific ERP Software)
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  29. 32. APPS PRODUCTION PLANING & CONTROL MODULE <ul><li>Production Process Planning </li></ul><ul><li>Production PO Generation </li></ul><ul><li>Lot Cut Plan Creation </li></ul><ul><li>Daily Cutting Tracking </li></ul><ul><li>Production Issue & Received Follow up </li></ul><ul><li>Finished Goods Received Tracking </li></ul><ul><li>WIP Transfer </li></ul><ul><li>Daily Production Report Generation </li></ul><ul><li>Production Summary Generation </li></ul><ul><li>Vendor Payment Tally Sheet Generation </li></ul>
  30. 33. APPS 8i -Features <ul><li>Efficiency Planning </li></ul><ul><li>Unit Resource Planning </li></ul><ul><li>Machine Planning </li></ul><ul><li>Target Setting </li></ul><ul><li>Master Plan generation </li></ul><ul><li>Production Plan Report </li></ul><ul><li>Machine Allocation status </li></ul><ul><li>Daily Plan details </li></ul><ul><li>Order Plan details </li></ul><ul><li>Planned Vs. Actual </li></ul>
  31. 34. Thank You!!!