Process Manufacturing

Agenda

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

Challenges
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)

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

Traditional vs New Approach

Traditional Through MPS and MRP Exensys is sensitive to present needs Present Approach

Basic or no Production Planning

Through -(CRP) Capacity Lack of Capacity Verification MPS - Master Planning Production Requirement Scheduling -(RCCP) Rough-cut Absence of Inventory Planning MRP Material Capacity Exensys Planning Production Requirements Planning Order module Lack of Control-Shop Floor enables Activities Controlling of Shop WIP can be tracked at all Floor Activities stages the help of Cannot Trace WIP with Efficient Processes PAC (Production Activity Control) Lack of Analysis Production Stages ATP: Availability to Promise (Customers can be promised of delivery times based on the Cannot Commit to Customers Available Inventory) CTP: Capability to Promise

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

Process Manufacturing

Process Manufacturing
SOP Manufacturing Cycle Sales and Operations Planning
Input: Forecasting

Optional Process

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

Process Manufacturing
SOP MS

Manufacturin g Cycle

Master Scheduling
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

Process Manufacturing
SOP MS Manufacturin g Cycle Master Production Scheduling
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

MPS

Process Manufacturing
SOP MS

Master Production Scheduling

Input: Approved master scheduling

MPS

Manufacturing Cycle

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

Process Manufacturing
SOP MS Rough-cut Capacity Planning
Input: MPS items Logic: 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

MPS

RCCP

Manufacturing Cycle

Process Manufacturing
SOP MS

Material Requirements Planning

Input: Firm MPS Logic: 1. BOM explosion
2. Offsetting of MRP items 3. Net requirements calculation 4. MRP record generation

MP S

RCCP

Manufacturing Cycle

Output: Input to CRP

Input to planned orders for procured items

MRP

Process Manufacturing
SOP MS Capacity Requirements Planning
Input: MRP firm dates for manufactured items Logic: 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

MPS

RCCP

Manufacturin g Cycle

MRP CRP

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

MPS

RCCP

Manufacturing Cycle

Planned orders

MRP CRP

Process Manufacturing

SOP MS

Manufacturin g Cycle

Process Order Generation/ Release

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

MP S

Production can also be generated without any planning (manual)

Process orders

RCCP

Planned orders

MRP CRP

Process Manufacturing
SOP

Manufacturing Cycle
Shop floor reporting

MS

Shop floor Reporting

MPS

Input: Completed operations Logic: 1. Material details 2. Machine details 3. Quantity produced Production Output: Status of production order orders

RCCP

Production can also be generated without any planning (manual)

Planned orders

MRP CRP

Process Manufacturing
Order Confirmation

SOP

MS

Production Order Settlement

Manufacturing Cycle

Production can also be generated without any planning (manual)

Shop floor reporting Input: Completed production orders Logic: 1. All operations completion 2. Required QC check completion 3. Quantity settled Process 4 Partial/Full Confirmation orders 5 Lot Number Output: Completed production orders

MPS

RCCP

Planned orders CRP

MRP

Process Manufacturing
Order settlement

SOP MS

Input to SOP and MS

Manufacturing Cycle

Shop floor reporting Input: Backlog orders Logic: 1. SOP production plan calculation 2. Master scheduling for customer orders Process Output: Initiation of SOP and MS orders

MPS

RCCP

Production can also be generated without any planning (manual)

Planned orders CRP

MRP

Modules
Order settlement

SOP MS

Shop floor reporting

Process orders

Master Execution Planning and Control Detailed of of Resources Scheduling and Resources planning

MPS

RCCP

Manufacturing Cycle

Planned orders CRP

MRP

Modules
Manufacturing It consists of two sub modules: Production Planning Production Activity Control Production Planning Production Activity Control

Modules
Production Planning

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

Detailed Scheduling and Planning MRP Run MRP Record Capacity Requirement Planning

Firm MPS

Confirm Planned Orders

Release Planned Orders

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, 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

Verticals
Industry Vertical

Pharmaceuticals Paints

Wood

Minerals
Paper and Pulp Printing Publishing Consumables Food, Beverages and Tobacco

Chemicals
Petroleum Coal Textiles and Apparel Metal

Thank you