Process Manufacturing

Agend a

Challenges Present scenario

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

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, 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

Through MPS and MRP Basic or no Production Planning Through -(CRP) Capacity Lack of Capacity Verification MPS - 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 AnalysisProduction 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

Process Manufacturing

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

Optional Process

Logic: 1. Preliminary SOP is prepared

2. 3. 4. 5. Sales/Production/Inventory plan Resource is planned and leveled Firm production plan is arrived Production plan is allocated

Output: Allocated production plan

Process Manufacturing
SO P MS Master Scheduling
Input: Firm Production Plan, Sales order
Services etc, Project, Manual etc.,

Manufacturi ng Cycle

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
Manufactur ing Cycle

SOP MS

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
SO P MS

Master Production Scheduling

Input: Approved master scheduling

Manufacturi ng Cycle

MP S

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

SO P

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

MP S

RCCP

Manufacturi ng Cycle

Process Manufacturing
SO P MS

Material Requirements Planning Input: Firm MPS

Logic: 1. BOM explosion

MP S

2. Offsetting of MRP items 3. Net requirements calculation 4. MRP record generation

Manufacturi ng Cycle

RCCP

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 MP items S Logic: 1. 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

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

Manufacturi ng Cycle

Planned 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. 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
SOP

Manufacturi ng 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 Confirmati on

SOP MS

Shop floor Manufacturi reporting Input: Completed production orders ng Cycle Logic: 1. All operations completion 2. Required QC check completion 3. 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, 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

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