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myNexgen ERP Production Process

myNexgen ERP Production Process. Nexgen Infosystems Private Limited. myNexgen ERP. Complementary Products. Tools & Utilities. Sales Sales Forecast & Analysis Sales Order Shipping. Discrete Production Product Definition Planning & Execution Engineering Change Control.

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myNexgen ERP Production Process

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  1. myNexgen ERP Production Process NexgenInfosystems Private Limited

  2. myNexgen ERP Complementary Products Tools & Utilities Sales Sales Forecast & Analysis Sales Order Shipping Discrete Production Product Definition Planning & Execution Engineering Change Control Human Resources Personnel Benefits Payroll Training Financials Accounts Receivable Accounts Payable Fixed Assets General Ledger Mgmt. Accounting Maintenance Equipment Maintenance Operations Logistics Inventory Purchasing Physical Inventory & Cycle Count Sub Contracting Administration

  3. Roadmap • Advantages • Core Concepts • Core Processes • Key Features • Integration • Benefits Advantages

  4. myNexgen ERP Process Production • Effective planning of resources • Capacity • Material • Meets statutory requirements • Lot traceability • Expiry dates etc... • Recipe / formula management • Alternate recipes • Attribute handling • Global change

  5. myNexgen ERP Process Production... • Links demand to sales and tracks progress of such production orders • Flexible • Planning options • Scheduling options • Allocation and picking options • Tracks costs at all stages of production • Nomenclature conforms to ISA S88 standard for batch production

  6. Core concepts • Configuring (modeling) • Measurement ID • Recipe   

  7. Process stage Planning Recipe Process Center Production Recipe Resource Process unit Accessory Human Resource Parameter Modeling

  8. Process unit Loading group Input / Output Parameter Resources Human Resource Accessory Modeling... Multi Process center

  9. Process Network Modeling... • Process stages linked using primary output defined Process stage 1 Process stage 3 Process stage 2 Process stage n Process stage 4 Process stage 5

  10. Pressure Measurement ID(MID) • MID is a combination of a process unit and parameter Measurement ID (MID) 1 Process Unit 1 Material Flow Temperature

  11. Recipe • Provides levels of recipe • Planning recipe - for MRP • Production recipe - for production • Production order recipe • Attribute based quantity determination (potency / assay) • Handles co-products / by-products • Enables recycling • Process parameters at recipe level • Global change

  12. Sales order & Forecast Eqp 1 Eqp 3 Modeling Shipping Eqp 2 Planning Purchase PRs & SCRs Aug 4 Scheduling Inventory Shop floor, execution & control To shop floor Core processes

  13. Core processes... • Planning • Execution • Analysis   

  14. Sales Ord.1 --- --- --- --- --- --- 1600 1600 Purchasing 1600 1200 jan feb mar apr Planning Salesforecast Salesorder Seasonalbuild • Calendar Productionschedule RCCP • BOM • Routing • PO rules Firmedproductionorder MRP

  15. Rough cut capacity planning (RCCP) • Long-term capacity planning • Flexible planning horizon / periods • Projects capacity load profile based on forecast / orders • Aids in identifying bottlenecks

  16. Planning parameters • Production order rules • Order policy : POQ, LFL, FOQ • Minimum order, maximum order qty • Order multiple • Optional production order against forecast • Multiple sources of supply

  17. Demand Firmedsupply Stockon hand Seasonalbuild MRP Exception Messages ! • BOM • Batch size • Disposition • Sources of supply • Prod. order rules Net Requirement 70 60 50 40 30 20 10 0 Per. 1 Per. 2 Per. 3 Per. 4 Productionorder Subcontractrequest Purchase request MRP

  18. 100 80 60 40 20 0 Per. 1 Per. 2 Per. 3 Per. 4 Sources of supply NET REQUIREMENT Year : 1998 Period : 3 Net requirement : 100,000 units 50% 20% 30% Sources of supply Purchased Manufactured Subcontracted 50,000 units 20,000 units 30,000 units

  19. To shop floor To shop floor To shop floor Available capacity Maintenanceschedule 30 20 10 0 PU 4 PU 1 PU 2 PU 3 ! Finite schedule Aug 4 Finite scheduling Production order release Firm reserved production Order • Prd ord amendment • Schedule constraints • Prd ord - recipe change • Prd ord - scheduling option NO YES YES Material Reservation Capacity exceptions Scheduled Production Orders NO Material exceptions

  20. Finite scheduling... • Finite backward / forward scheduling • Optional material reservation check • Displays capacity and material exceptions • Specify production order level capacity constraints • Optionally amend production order recipe, quantity and due date • Hold production orders

  21. Finite scheduling...Rules • Finite scheduling - user-defined rules • Scheduling method : forward / backward • Load splitting • Partial loading • Overlapping • Combining orders (multi process center) • Order priority • Process units - deployment rules • Horizon step

  22. 1 Finite scheduling... ? 1 PS 1 PS 2 PS 3 2 2 3 3 Today Time Already loaded Backwardscheduling Forward scheduling to define new end date

  23. To shop floor Shop floor execution & control Production order release Hard allocation  Process stage, execution & ctrl. Quality clearance Movement to inventory Close/short close production order Shipping SPC / SQC

  24. Hard allocation • Methods • LIFO • FIFO • Max. zone bin • Min. zone bin • Expiry date • Attribute based • User-defined

  25. Hard allocation... • Scale up based on lot level attribute value (potency / assay) • Picking based on multiple attributes • Allows bulk / automatic allocation • Provision to de-allocate and reallocate • Generates pick sheet based on options specified

  26. Production order Release • Indicates material availability for reservation to Ramco Sales • Enables Ramco Management Accounting to track costs for the production order

  27. Production orderExecution and control • Executes different process stages for a order, captures data on • Batch details • Material production and consumption • Human resources / accessory deployed • Costing activity details • Stoppage details • Enables QC clearance of produced items and movement to storage / warehouse

  28. Production orderCosting • Activity based costing • User-defined costing activities • Tracks manpower, machinery and accessory costs

  29. Production orderClose / short close • Order settlement in Ramco Management Accounting • De-reserves stocks, capacity on short closure • Passes information to Ramco Sales if production order - sales order link exists

  30. Analysis • Rough cut capacity analysis • MRP summary • Raw material requirement analysis • Finite scheduling - scheduling chart • Capacity / material exceptions • Costing analysis - cost sheet

  31. Analysis... • Online process parameters analysis • Quality clearance (QC) analysis • WIP inventory analysis • Lot tracking • Where-used analysis

  32. Key features • Integration with process control systems • Multi-process unit • Production order life cycle • Production order decoupling • Raw material (RM) availability check • Backflushing • Lot tracking • Where-used analysis        

  33. Integration with process control systems Ramco PP Process Unit Parameter Measurement ID Interface DCS

  34. Fisher Process control information architecture • Windows 3.1 • Windows 95 • Windows NT • Client applications Ramco Business management Real Time Integrator (RTI) • Windows NT • Operator console • RT/ history data • Server Plant highway • Windows NT • RT/ history data • Server • Windows NT • Operator console Plant highway Process management Fieldbus Controller Field management • Measurement • Pressure • Temp • Flow • Level Coriolis • Analytical • Simple • Complex HandheldPDA • Analog I/O • Digital I/O • TC/RTD Configuration &maintenance PD metersCommon head Valvespositioners

  35. Multi-process unit Input 2 Input 3 Input 1 Multi-Process Unit Output 2 Output 3 Output 1 • Simultaneous process of multiple items • Loading group • Continuous / batch • Capacity factor Product 2 Product 3 Product 1

  36. Firm Up Firmedproduction order Plannedproduction order MRP Manually created Firm scheduled production order Schedule Scheduled production order Firm Schedule Short close /close production order Hold Released order Complete production Production order life cycle Release

  37. Production order decoupling Production Order 1 Process stage 1 Process stage 2 Process stage 3 Rawmaterial Intermediate 3 Decouplingpoint Production Order 2 Process stage 4 Process stage 5 Process stage 6 Finishedgoods

  38. MRP run Scheduling MRP Reservation PR Execution Exception messages Firm reservation Allocation Exception messages Production execution Hold prd ord RM availability check

  39. FG 1 100 units (Reporting produced quantity) Input item Qty req. Qty alloc. Qty issued Qty consumed RMIXT 200 200 200 200 RM2YC 50 50 50 50 - - RM3BF 100 100 RMXB1 70 70 70 70 Backflushing Finished goods Details • Updates Ramco Inventory automatically based on reported consumed quantity Recipe

  40. Inter 1 Lot Y232 Inter 2 Lot Y232 Inter 3 Lot Y232 RM 1 / 001 /198 / M1 RM 4 / 001 /198 / M1 RM 5 / 001 /198 / M1 RM 2 / 002 / 198 M1 RM 3 / 002 / 198 M1 RM 6 / 002 / 198 M1 Lot tracking FG – LOT XY0001 Drilldown from FG lot level to the lowest detail level RM - Raw material Inter - Intermediate FG - Finished goods

  41. Where-used analysis RM 3 / 0000001/98/M1 • Displays FG lots which have consumed a particular raw material lot FG 1 Lot 001/198 FG 2 Lot 002/198 FG 3 Lot 003/198

  42. Sales Inventory & Purchase Ramco Process Production myNexgen ERP Process Production • Sales forecast & orders • Sales order-production order linkage • Item details • Reservation • Hard allocation • Issues & receipts • Purchase requests SPC/SQC General Ledger & MAC • Production reporting • In-process analysis • QC clearance • Financial postings • Cost Centers • Activity cost element • Activity std. rates • Order / batch costing

  43. PP myNexgen ERP Process Production... Ramco Process Production Maintenance RTI • Equipment details • Preventive maintenance schedules • Maintenance forecast • Run hour updation • Work request • Capture Process parameters • Item consumption / production details

  44. myNexgen ERP Process Production • Eliminates supply chain bottlenecks due to integration with other Ramco applications • Planning and scheduling systems enable effective inventory management • Improved product cost visibility • Integrates with process control systems

  45. Roadmap • Advantages • Core Concepts • Core Processes • Key Features • Integration • Benefits

  46. Thank you

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