Traditionally production planning software was a separate package or an independingly functioning module in Enterprise. The level of administration needed was high and reporting took a long time.
Enterprise has a different approach to supporting MRP production planning. Being tightly integrated to other processes makes the information support to production very efficient. It uses the same principle as other modules and processes, so it is very easy to add production to an existing installation.
You will be able to run all standard production operations like technology base, production logistics, planning and scheduling. On top of that you will find out how easy it is to handle and track batches and serial numbers. A part of supported quality management processes are easy tracking of working hours and productivity through CRM integration and easily getting very detailed post-calculation and other statistics reports, which take a long time to create in competitive solutions.
Table of Contents. ERP system for manufacturing
HansaWorld uses a concept called Recipes for assembly management, bill of materials and formulations. Recipes control:
- which raw materials or sub-assemblies will be used for finished goods or other sub-assemblies
- which costs will be used during the Production process for cost accounting
- how long the Production process is planned to take
- minimum and normal production quantities, also to assist in the planning process
Standard labour can be included on Recipes. Multi-level assembly reporting includes:
- listings of which raw materials are needed for each subassembly or finished item, and at which level
- listings of which raw materials and sub-assemblies are required for a specific finished item or sub-assembly
- which sub-assemblies or finished items use a specific raw material or sub-assembly
- costs associated with each sub-assembly or finished item
- how many of a specific sub-assembly or finished item can be produced.
Machines, Machine Usage and Capacity Planning
Machines are set up in HansaWorld’s Fixed Asset module. This controls not only the accounting for the machine, with different rates for automated depreciation calculations and for tax reporting, and a variety of pieces of relevant data about the machine, but also allows costs to be set for each hour the machine is running, and each hour the machine is idle.
To assist in the planning process, you can set which machines will support the production of each Recipe. If it is ever necessary to produce a sub-assembly or finished item on a machine other than the default, HansaWorld can be configured to use a different Recipe, thereby reflecting the different speeds or capacities of each machine.
The planning process is brought together by Production Orders. Any work that is to be scheduled needs to be entered as a Production Order. HansaWorld then automatically allocates Production Orders to default machines, and automatically assigns a place in the production queue. Both these allocations can be overridden manually. The schedule for machines can then be viewed from the graphical Resource Planner. Drill down from individual machines to specific Production Orders. Rearrange the schedule by drilling down and running a routine to reassign Queue Positions (you specify which Queue Position you want the current Production Order assigned to), or by drag and drop to another machine.
Production Orders also store both the total planned duration of the specific assembly, and the actual time taken - this latter time is automatically entered by HansaWorld when the Production Order is marked as Finished.
The Production record in HansaWorld's manufacturing ERP system performs the changing of stock quantities (decrementing raw materials and incrementing assemblies or finished goods), and any associated accounting. Enter onto the Production how many of a particular Recipe you want to produce, and HansaWorld will split serial numbered items down to separate lines for each serial number. There is even a function for HansaWorld automatically to generate the serial numbers for each line.
HansaWorld handles wastage by allowing Productions to be discarded. The user is forced to enter a reason for the discard - from a selection of standard problems previously defined. The Inspector of each batch is also recorded. Productions can be created automatically from Production Orders. This function is sensitive to batch sizes already predefined in the software, when items are batch tracked.
Productions can be created automatically from Production Orders. This function is sensitive to batch sizes already predefined in the software, when items are batch tracked.
Assemblies and Finished Goods can even be “disassembled?- this creates a new Production with the reverse entries from the original Production
For “specials? it is not mandatory to put a Recipe on a Production. Entries of raw materials (in) and assemblies/finished items (out) can be made directly to the Production, thereby reducing the duplication between the Recipe and the Production. Standard reports include answers to such questions as:
- Are there enough raw materials to make a range of Production?
- Which raw materials purchases must be made to support a range of Productions?
HansaWorld's ERP manufacturing system provides automated features for forward purchases of raw materials, and scheduling, all from Sales Orders. Lead times can be stored for each component item, with different lead times available for each supplier. Default suppliers for each item can also be set. Similarly the standard length of time to manufacture is stored on each Recipe, for use on Production Orders or Productions. There is a batch routine that brings this all together, by working back from the scheduled delivery date, and creating forward Production Orders (for example) to schedule the manufacture in time to deliver by the scheduled delivery date, and creating forward Purchase Orders in time to meet the scheduled Production Orders.
Materials Requirements Planning (MRP)
There are several reports and batch routines to assist in the materials purchasing process. See HansaWorld's purchasing software and procurement software for further details.
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