You are on page 1of 28

Process Manufacturing

Agend a
        

Challenges Present scenario

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

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.Challeng es 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.  Overheads Management (trace utility consumption for costing)  Recipe Security (patents) .

Present Scenario          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 .

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

Master Requirement Production Planning Absence of Inventory Planning Scheduling -(RCCP) Rough-cut Exensys’ Production MRP – Material Capacity Planning Order module Lack of Control-Shop Floor Activities Requirements enables Controlling Planning WIP can be tracked of Shop Floor at all stages with Cannot Trace WIP Activities – Efficient the help of PAC Processes (Production Activity Lack of Analysis–Production Stages ATP: Availability to Promise Control) (Customers can be promised of delivery times Cannot Commit to Customers based on the Available Inventory) CTP: Capability to Promise Traditional Exensys is sensitive to present needs Present Approach 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 .Traditional vs New Approach Through MPS and MRP Basic or no Production Planning Through -(CRP) Capacity Lack of Capacity Verification MPS .

Process Manufacturing .

Process Manufacturing SOP Manufacturi ng Cycle Sales and Operations Planning Input: Forecasting Optional Process Logic: 1. Preliminary SOP is prepared 2. Sales/Production/Inventory plan Resource is planned and leveled Firm production plan is arrived Production plan is allocated Output: Allocated production plan . 5. 3. 4.

Manufacturi ng Cycle Logic: 1.. Manual etc. Planning required Yes/No entered Output: Work flow approved master scheduling .Process Manufacturing SO P MS Master Scheduling Input: Firm Production Plan. Items are selected from references 3. Expected date and quantity entered 4. Planning horizon entered 2. Sales order Services etc. Project.

PAB and scheduled receipts are considered to calculate net requirements Output: Input to RCCP Input to ATP based on MPS MPS .Process Manufacturing Manufactur ing Cycle SOP MS Master Production Scheduling Input: Approved master scheduling Logic: 1. Preliminary MPS calculated 4. Planning period entered 2. Bucket / Bucket less planning 3.

Preliminary MPS calculated 4. Bucket/Bucket less planning 3. PAB and scheduled receipts are considered to calculate net requirements Output: Input to RCCP Input to ATP based on MPS .Process Manufacturing SO P MS Master Production Scheduling Input: Approved master scheduling Manufacturi ng Cycle MP S Logic: 1. Planning period entered 2.

Scheduling type defined 2. Start date/end date of all manufacturing items calculation 3. Firm MPS quantities arrived Output: Firm MPS quantities Input to MRP MP S RCCP Manufacturi ng Cycle .Process Manufacturing SO P MS Rough-cut Capacity Planning Input: MPS items Logic: 1. RCCP quantity finalized based on load 5. Load of work center calculated 4.

Process Manufacturing SO P MS Material Requirements Planning Input: Firm MPS Logic: 1. MRP record generation Manufacturi ng Cycle RCCP Output: Input to CRP Input to planned orders for procured items MRP . Net requirements calculation 4. Offsetting of MRP items 3. BOM explosion MP S 2.

Operation wise start date/ end date calculation 2. Work center load calculation 3. Finalization of operation start/ RCCP end date based on load Output: Firm start/end date for manufactured items Manufactur ing Cycle MRP CRP .Process Manufacturing SOP MS Capacity Requirements Planning Input: MRP firm dates for manufactured MP items S Logic: 1.

Process Manufacturing SOP MS Planned Orders – Confirm/ Release Input: MRP for procured items CRP for manufactured items Logic: 1. Release planned orders Output: Input to purchase indent Input to production orders MPS RCCP Manufacturi ng Cycle Planned orders MRP CRP . Confirmation of planned orders 2.

Order release for all operations 3. PO items release Process RCCP Output: Item request to inventory Production can also be generated without any planning (manual) orders Planne d orders MRP CRP .Process Manufacturing SO P MS Manufacturi ng Cycle Process Order Generation/ Input: Released planned orders Release Logic: 1. Production order generation MP S 2.

Process Manufacturing SOP Manufacturi ng Cycle Shop floor reporting MS Shop floor Reporting MPS Input: Completed operations Logic: 1. Quantity produced Production Output: Status of production order orders RCCP Production can also be generated without any planning (manual) Planned orders MRP CRP . Material details 2. Machine details 3.

Process Manufacturing Order Confirmati on SOP MS Shop floor Manufacturi reporting Input: Completed production orders ng Cycle Logic: 1. Required QC check completion 3. All operations completion 2. Quantity settled Process 4 Partial/Full Confirmation orders 5 Lot Number Production can Output: Completed production orders Production Order Settlement MPS RCCP also be generated without any planning (manual) Planned orders MRP CRP .

Process Manufacturing Order settlemen t SOP MS Manufacturi ng Cycle Shop floor MPS reporting Input: Backlog orders Logic: 1. SOP production plan calculation 2. Master scheduling for customer orders Process RCCP Output: Initiation of SOP and MS orders Input to SOP and MS Production can also be generated without any planning (manual) Planned orders MRP CRP .

Module s Order settleme nt Shop floor reporting Process orders SO P MS Master Execution Planning and Control Detailed of of Scheduling Resource Resources and planning s MP S RCCP Manufacturi ng Cycle Planne d orders MRP CRP .

Modul es It consists of two sub modules:  Production Planning  Production Activity Control Manufacturing Production Planning Production Activity Control .

Module s Master Planning of Resources Production Planning Detailed Scheduling and Planning •MRP Run •MRP Record •Capacity Requirement Planning •Confirm Planned Orders •Release Planned Orders • 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 .

Modules Production Activity Control  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 .

Exensys Supports Industry Best Practices  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      .

Advantage eXensys Domain Expertise Extensive domain knowledge. Quality in Process Transparent development methodologies through metrics-based management to control costs and quality. leading to reduced time to market. Mastermind Re-engineering Optimization of business processes. to understand the business problem and suggest optimal business solutions. . by re-engineering critical functions across the entire value chain.

with flexibility in choosing models Strong Roots Improved bottom-line operational efficiency and meet new .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.

Vertical s Industry Vertical Pharmaceuticals Paints Chemicals Petroleum Coal Textiles and Apparel Metal Wood Minerals Paper and Pulp Printing Publishing Consumables Food. Beverages and Tobacco .

Thank you .