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BatchMaster Enterprise

BatchMaster Enterprise. Training Program Manufacturing. Forecast Entry (Mfg.). Warehouse Transfer (Distr.). Demand. Forecast Entry. Dependant Demand. All Dependant Demand. Exception Orders. Run MPS *. Warehouse Transfers. Buy. Make. Sales Orders. Planned Purchase Order.

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BatchMaster Enterprise

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  1. BatchMaster Enterprise TrainingProgram Manufacturing

  2. Forecast Entry (Mfg.) Warehouse Transfer (Distr.) Demand Forecast Entry Dependant Demand All Dependant Demand Exception Orders Run MPS* Warehouse Transfers Buy Make Sales Orders Planned Purchase Order Planned Prodn Order Run MRP* Transfer to PO Transfer to Batch Planned Purchase Order Planned Production Order PO Receipt Batch Issue … … Raises On Hand Batch Close Dispatch Raises On Hand Dispatch Sales Order * Checks Supply also: - On Hand - Production orders - Purchase orders Buy/Make is defined in Item Master

  3. Running MPS Forecast Planned Production Orders Run MPS Warehouse Transfers* Planned Purchase Orders Customer Orders* OR * via BME Distribution Application

  4. Modules in BME Manufacturing Application

  5. MPS: Run MPS 2 5 5 5 5 5 5 1-2 1 1 1-2 3 4

  6. MPS: Company Calendar Setup • Select Year and Weekly Holidays • Click on “Process” button. • Check the boxes specific holiday dates Different from ‘Period Dates’ which are used for salesman commission etc.

  7. MPS: Planning Calendar

  8. MPS: Maintain MPS Item To Maintain MPS Item, the ‘Order Method’ of that item must be set to ‘MPS’in the Item Master screen. Batches are generated for ‘Manufacture’ Purchase Orders are generated for ‘Purchase’ * Lowest occurrence (largest number) for this item among all MPS items. * Enabled for ‘Purchase” *Overrides the value set in ItemLocation

  9. MPS: MPS Setup In a Fence: NO planned purchase/production orders can be generated. Only Exception Orders can be generated. Both fences are optional, a company may set up either on none.

  10. MPS: Forecast Entry Insert Forecast Fill Forecast Zero Forecast This screen enters forecast for MPS and MRP Items. From Item Location = not considered in MPS/MRP run = for future version, currently similar to Active

  11. MPS: Forecast Entry …2 Creates Forecast according to Production History* Creates Forecast according to Sales History** Based on dates of : * P-type transactions ** S-type transactions

  12. MPS: Forecast Entry …3

  13. MPS: Run MPS Fill the values for the various parameters. Click on the “Process” button. Click “OK” on the confirmation message box. Another message box appears with a ‘success’ message. Forecasts with this calendar key are factored into MPS run.

  14. MPS: MPS Planning Worksheet …1 Total Order Release = Planned + Firm Planned + Confirmed Orders MPS  Receipt on Planned + Firm Planned + Confirmed Orders; (not “Transferred” yet) Production/Purchase Orders  Receipt on Production/Purchase Orders placed previously

  15. MPS: MPS Planning Worksheet …2 • For various ItemLocations, the Forecast, Customer Orders, and Warehouse Transfers can be seen on their respective tabs on this screen. • Convert to ‘Firm Planned’ or ‘Confirmed’ the various • ‘Planned’ Production Orders (for Make-type items having a Released BOM) or • ‘Planned’ Purchase Orders (for Buy-type items) Planned: Can be changed by another MPS run. Can NOT be transferred to PO/Batch Firm Planned: Can NOT be changed by another MPS run. Can NOT be transferred to PO/Batch Confirmed: Can NOT be changed by another MPS run. Can be transferred to PO/Batch

  16. MPS: Transfer MPS Purchase Order • Select MPS Item(s) and Location(s), and click on the “Process” button. • For specific ItemLocations, select a Vendor. • ‘Check’ the specific ItemLocation(s), click on the “Transfer PO” button. • A report lists the Purchase Orders generated.

  17. MPS: Transfer MPS Production Order …1 • Select MPS Item(s) and Location(s), and click on the “Process” button. • Click on the ellipsis button and enter values in the new box for: BatchNo, BatchType,Intermediate (for Fill type), Process Cell (required for ‘Mix’ type batches, Measured by Wt or Vol, Cell Capacity.(“Select in Range” can be used to do the same for several lines highlighted in blue) • Click on “Transfer to Batch” button.(a report is generated on batches created)

  18. MPS: Demand Fence 1 MPS Purchase Order MPS: Demand Fence 1 MPS Production Order MPS: Demand Fence 2 MPS Purchase Order MPS: Demand Fence 2 MPS Production Order • These four screens are almost similar in use and appearance. • Orders can be converted from ‘Exception’ to “Firm Planned” or “Confirmed”. • A person ‘Confirming’ orders in Fence 1 has access to confirming Fence 2 orders too on his/her screen (not vice versa) (since the Fence1 person may have a higher approval level). • Confirmed orders can then be Transferred to Purchase Orders on Production Orders.

  19. MRP These screens are analogous to the MPS module screens.

  20. Filling Production Orders • To Manufacture products, we need ‘BOM’ (Bill Of Materials). • Mix (Ingredients are directly added into packaging container) • Fill (pre-made Intermediate is added into packaging container) • Assembly (to pack Finished Goods, e.g., bottles in a case). • Mix/Fill BOM’s require a ‘Formula’.

  21. Formula 1 1 1 1 1 1 1 1 1 2 • Formula is required for Finished Good and Intermediate assembly-type BOM’s. • Formula should also be created for hazardous intermediates of “Buy” type, for the purpose of MSDS compliance on reportable hazardous ingredients.

  22. Formula: Formula Class

  23. Formula: Formula Status The Formula Status here is a ‘flag’ attached to the formula. It is used for - MSDS Schedule Generation to print MSDS. - Production can be set up to prevent batch creation for selected formula status.

  24. Formula: Boilerplate Instruction

  25. Formula: Process Cell

  26. Formula: Overhead Cost

  27. Formula: Labor/Additional Cost

  28. Formula: Printed Master Formula Boilerplate …1 BP is displayed with line items.

  29. Formula: Printed Master Formula Boilerplate …2 Section #1 Section #2 Section #3

  30. Formula: Printed Master Formula Layout …1 Used when a formula is printed. First N lines are printed as specified here The Formula Notes come from Formula Entry screen (Formula Master tab).

  31. Formula: Printed Master Formula Layout …1 Not Rounded  Truncated to “6.4” format Used when a formula is printed. Only Decimal is used currently. Own Line / Description Line (with Description Line, an indentis inserted before BP is printed.)

  32. Formula: Printed Master Formula Layout …2 forces a Page Break for QC section When Formula is printed.

  33. Formula: Formula Defaults …1 Values entered here will be automatically included in subsequently generated formulas.

  34. Formula: Formula Defaults …2 Values entered here will be automatically included in subsequently generated formulas.

  35. Formula: Formula Entry - 1. Formula Master Used if ingredient densities are not known, or if there is change is density / sp. gr. / bulkingfactor for reasons such as a chemical reaction. Formula can be printed directly via “Print” button. Unsaved Formula can also be printed with the latest values from the screen.

  36. Formula: Formula Entry - 2. Cost Fixed Costs Overhead: $ type: Multiplied by no. of Fixed (or Setup) cost hrs % type: % of the total Fixed labor (or Setup) labor cost. Setup Costs Overhead: $ type: Multiplied by no. of Fixed (or Setup) cost hrs % type: % of the total Fixed labor (or Setup) labor cost. Variable Cost: the ‘Amount’ applies to Total batch Weight in Maxwt range. (in example below, $1 is variable cost for Total batch Weight  100 lb.) Variable Labor Overhead: $ type: Factor Multiplied by Batch weight in ‘System Weight UOM’ % type: % of the corresponding labor cost.

  37. Formula: Formula Entry - 3. Safety Used if the formula produces something fundamentally different from the components, e.g, Na + Cl  NaCl. (MSDS related) Informationto print on MSDS

  38. Formula: Formula Entry - 4. Line Items …(a) (up to 80 characters) Add Line: Adds a line at the bottom of all the lines. Insert Line: Inserts a line where a line-item is highlighted Create Line: Copies the highlighted line. Delete Line: Deletes the highlighted line Total Volume = Total Weight * (Density Override OR System UOM Conversion Factor)

  39. Formula: Formula Entry - 4. Line Items …(b) Calculation of amount in costing is based on Labor: Qty Required (of Labor line item) * CostAmount (rate) Labor Overhead in %: percent of above Labor amount Labor Overhead in $: Qty Required (of Labor line item) * O/H-CostAmount (rate) Material Overhead in %: percent of material line’s amount Material Overhead in $ : Factor * Line Item Qty in Stock UOM Costing Method for materials will be Standard or Average, as defined in Default Setup (in Application Setup module).

  40. Formula: Formula Entry - 4. Line Items …(c) Toggle Costs Opens ‘QC Formula Tests’ screen. Toggle Costs: Toggles between Standard, Average, Last (for all ingredients and byproducts simultaneously) Size Formula: Resizes the formula and materials to desired weight/volume. One formula can be used to create another formula.

  41. Formula: Formula Entry - 5. By Products

  42. Formula Utilities

  43. Formula Utilities: Compare Prior With Present Select a prior formula via “Lookup” button.

  44. Formula Utilities: Revert to Prior Version This utility creates a New formula identical to a prior formula selected via lookup.

  45. Formula Utilities: Intermediate Expansion …1 Before Expansion After Expansion C A A D E B C B D E ByProdC ByProdC ByProdA ByProdA • - Suppose Material C is made with Materials D and E. • Formula A uses materials B and C. • Intermediate Expansion (in Formula A) of formula Item C replaces C with D, E. - Similarly, expansions can be done for By Products. In that case: When C is expanded, its by product(s) also get listed in Formula A.

  46. Formula Utilities: Intermediate Expansion …2 (one material is expanded at a time) Checks whether expansion can be done, provides report. Does the actual expansion (changes the formula), provides report.

  47. Formula Utilities: Material Substitution …1 • There may be a need to replace a specific material by another in some formula / formulas. • The user may want to: • Replace a material in the selected formula(s) • With no added criteria, or • Only if another specific material is also present (e.g. in case of incompatibility). • Do the substitution by weight or by volume of original material • If there is a change in Total Weight or Volume, the user may • Make no further adjustments, or • Match Original Formula Weight or Volume by • Adjusting quantities of specific material only, or • Resize all the new formula items proportionately.

  48. Formula Utilities: Material Substitution …2 Useful to avoid incompatibilities, replace incompatible material with another suitable material Wt/Vol In case Wt or Vol needs to be adjusted to Original, Should the Entire Formula get resized, Or should a Specific Material get resized? ‘Manually’ asks for confirmation on each formula ‘Automatically’ does all substitution without reconfirmation

  49. Formula Utilities: Purge Prior Versions Checked means only Line Items and By Products are removed Unchecked means the whole formula is purged. Checked  Final Purge Unchecked  Trial Mode Purge Purges the selected formulas in the selected date range Purges the Latest N versions of selected formulas

  50. Formula Utilities: View Prior Version

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