Process Manufacturing

Challenges Present scenario Traditional vs New Approach Key Drivers Definition Solution: Process-wise Modules Best Practices Advantage Customers

Agenda

Competitive Pressures: Decreasing Production Volumes Increasing Product Variety Shortening of Product Life Cycles (PLC) Reducing Number of Repeat Orders

Manufacturing Processes: Flexible Manufacturing Systems (FMS) Balanced Manufacturing System

Considering Organization, People and Technology Skill-based Automated Manufacturing Systems

Process Industry: Variations Tracking (quality of inputs is inconsistent) Shelf Life Management (batch quarantine) Co/By-Product Mngmt. Overheads Management (trace utility consumption for costing) Recipe Security (patents)

Challenges

Competition and Cost Complex Supply Chain Complex Outsourcing Decisions Suppliers Competency Lacking Systems Integration Low Visibility No Compatibility Inefficient Business Analysis No Supply Chain Analysis

Present Scenario

Optimize Manufacturing Techniques On-time Supply Global Integration Customer Relationship Management Customer Information Management Effective Information Sharing Cost Competition Critical Market Share

Key Drivers

Basic or no Production Planning

Lack of Capacity Verification

Absence of Inventory Planning

Lack of Control-Shop Floor Activities

Cannot Trace WIP

Lack of Analysis–Production Stages

Cannot Commit to Customers

Traditional

Effective Production Planning

CRP, RP, RCCP

Net Planning in MPS and MRP

Production Order

WIP Tracking at all Stages

Analysis at all stages

ATP & CTP

Present ApproachExensys is sensitive to present needs

Through MPS and MRP

Through -(CRP) Capacity Requirement Planning-(RCCP) Rough-cut Capacity Planning

MPS - Master ProductionSchedulingMRP – Material Requirements Planning

Exensys’ Production Order module enables Controlling of Shop Floor Activities – Efficient Processes

WIP can be tracked at all stages with the help of PAC (Production Activity Control)ATP: Availability to Promise (Customers can be promised of delivery times based on the Available Inventory)CTP: Capability to Promise

Traditional vs New Approach

Process Manufacturing

SOP

Input: Forecasting

Logic: 1. Preliminary SOP is prepared 2. Sales/Production/Inventory plan 3. Resource is planned and leveled 4. Firm production plan is arrived 5. Production plan is allocated

Output: Allocated production plan

Sales and Operations Planning

Optional Process

Manufacturing Cycle

Process Manufacturing

SOP

Input: Firm Production Plan, Sales order Services etc, Project, Manual etc.,

Logic: 1. Planning horizon entered 2. Items are selected from references 3. Expected date and quantity entered 4. Planning required Yes/No entered Output: Work flow approved master scheduling

MSMaster SchedulingManufacturi

ng Cycle

Process Manufacturing

SOP

Input: Approved master scheduling

Logic: 1. Planning period entered 2. Bucket / Bucket less planning 3. Preliminary MPS calculated 4. PAB and scheduled receipts are considered to calculate net requirements Output: Input to RCCP Input to ATP based on MPS

MSMaster ProductionScheduling

MPSManufacturing Cycle

Process Manufacturing

SOP

Input: Approved master scheduling

Logic: 1. Planning period entered 2. Bucket/Bucket less planning 3. Preliminary MPS calculated 4. PAB and scheduled receipts are considered to calculate net requirements Output: Input to RCCP Input to ATP based on MPS

MSMaster ProductionScheduling

MPSManufacturi

ng Cycle

Process Manufacturing

SOP

Input: MPS itemsLogic: 1. Scheduling type defined 2. Start date/end date of all manufacturing items calculation 3. Load of work center calculated 4. RCCP quantity finalized based on load 5. Firm MPS quantities arrived Output: Firm MPS quantities Input to MRP

MSRough-cut Capacity Planning

MPS

RCCP

Manufacturing Cycle

Process Manufacturing

SOP

Input: Firm MPSLogic: 1. BOM explosion 2. Offsetting of MRP items 3. Net requirements calculation 4. MRP record generation Output: Input to CRP Input to planned orders for procured items

MSMaterial RequirementsPlanning MP

S

RCCP

MRP

Manufacturing Cycle

Process Manufacturing

SOP

Input: MRP firm dates for manufactured itemsLogic: 1. Operation wise start date/ end date calculation 2. Work center load calculation 3. Finalization of operation start/ end date based on load Output: Firm start/end date for manufactured items

MSCapacity RequirementsPlanning

MPS

RCCP

CRPMRP

Manufacturing Cycle

Process Manufacturing

SOP

Input: MRP for procured items CRP for manufactured itemsLogic: 1. Confirmation of planned orders 2. Release planned ordersOutput: Input to purchase indent Input to production orders

MS

Planned Orders – Confirm/Release MPS

RCCP

Planned orders

CRPMRP

Manufacturing Cycle

Process Manufacturing

SOP

Input: Released planned ordersLogic: 1. Production order generation 2. Order release for all operations 3. PO items releaseOutput: Item request to inventory

MS

Process Order Generation/ Release

MPS

RCCP

Planned orders CRP

MRP

Process ordersProduction

can also be generatedwithout anyplanning (manual)

Manufacturing Cycle

Process Manufacturing

Production can also be generatedwithout anyplanning (manual)

SOP

Input: Completed operationsLogic: 1. Material details 2. Machine details 3. Quantity producedOutput: Status of production order

MS

Shop floor ReportingMPS

RCCP

Planned orders

CRPMRP

Production orders

Shop floorreporting

Manufacturing Cycle

Process Manufacturing

Production can also be generatedwithout anyplanning (manual)

SOP

Input: Completed production ordersLogic: 1. All operations completion 2. Required QC check completion 3. Quantity settled 4 Partial/Full Confirmation 5 Lot NumberOutput: Completed production orders

MS

Production Order Settlement MPS

RCCP

Planned orders

CRPMRP

Process orders

Shop floorreporting

OrderConfirmation

Manufacturing Cycle

Process Manufacturing

Manufacturing Cycle

Production can also be generatedwithout anyplanning (manual)

SOP

Input: Backlog ordersLogic: 1. SOP production plan calculation 2. Master scheduling for customer orders Output: Initiation of SOP and MS

MS

Input to SOP and MSMPS

RCCP

Planned orders

CRPMRP

Process orders

Shop floorreporting

Ordersettlement

Process Manufacturing

Manufacturing Cycle

Modules

SOP MS

MPS

RCCP

Planned orders CRP

MRP

Process orders

Shop floorreporting

Ordersettlement

Master Master Planning Planning

of of ResourceResource

ss

Detailed Detailed Scheduling Scheduling

and planningand planning

Execution Execution and Control and Control

of of ResourcesResources

It consists of two sub modules:

Production Planning

Production Activity Control

Manufacturing

Production Planning

Production Activity Control

Modules

Master Planning of Resources

• Manual Forecasting• Preliminary Sales and

Operations Planning• Resource Planning and

Leveling• Production Plan Allocation• Master Scheduling• Master Production

Scheduling• Rough-cut Capacity Planning• Firm MPS

Production Planning

Detailed Scheduling and Planning

•MRP Run

•MRP Record

•Capacity Requirement Planning

•Confirm Planned Orders

•Release Planned Orders

Modules

Execution and Control of Resources• Process Order Generation (POG)

• Availability Check (AC)• Production Order Release (POR)• Process Order – Item Release (POIR)• Shop Floor Instruction Sheet• Item Requisition – Planned Withdrawal• Item Requisition – Unplanned Withdrawal• Shop floor Reporting• Process Order Confirmation

Production Activity Control

Modules

SOP (Sales and Operations Planning)

Availability check before production order release

Capacity planning at each stage

Exception/transaction messages from MRP system

Production order status at any point of time

Effective integration with QC

Multilevel BOM

Exensys Supports Industry Best Practices

Domain Expertise

Extensive domain knowledge, to understand the business problem and suggest optimal business solutions.

Mastermind Re-engineering

Optimization of business processes, by re-engineering critical functions across the entire value chain.

Quality in Process

Transparent development methodologies through metrics-based management to control costs and quality, leading to reduced time to market.

Advantage eXensys

Perpetual Support

Global delivery and support capabilities for 24 x 7 uptime

Unmatchable Competencies

Proven capabilities in offshore methodology to bring down cost of IT ownership

Flexible Models

A partnership mode of engagement, with flexibility in choosing models

Strong Roots

Improved bottom-line operational efficiency and meet new performance objectives

Advantage eXensys

Verticals

PharmaceuticalsPaintsChemicalsPetroleumCoalTextiles and ApparelMetal

WoodMinerals

Paper and PulpPrinting

Publishing Consumables

Food, Beverages and Tobacco

Industry Vertical

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