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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
Thank you