Material Required Planning

• Bill of Material• Gross to Net Explosion• Lead Time Offsetting• Processing Frequency• Lot Sizing• Safety Stock• Safety Lead Time

Role of MRP Planner

• Release Orders / Schedules

• Reschedule Due Dates of Open Orders

• Analyse & update planning factors

• Reconcile inconsistances

• Prevent future crises

Capacity Planning

• Capacity Bills• Capacity Requirement Planning• Increase the Number of Shifts• Overtime authorisation• Hiring / Layoff• Add Machines / Tools • Subcontract• Capacity Utilisation

Master Production Scheduling

• Marketing/Production Co-ordination• Order Promising & Shipment Dates• Time phased MPS Record• Master Production Scheduler• Stability of MPS• Performance Measurement

ManufacturingManufacturing

Inventory Control

Inventory Control

Material Requirement

Planning

Material Requirement

Planning

Process Modelling

Process Modelling

Quality Control

Quality Control

Production Planning

Production Planning

PurchasingPurchasing

Manufacturing Modules

Production Management

Production Management

ManufacturingManufacturing

SalesSales

Distribution Planning

Distribution Planning

Excise/CenvatExcise/Cenvat

Finished Goods

Inventory

Finished Goods

Inventory

Exports Management

Exports Management

MarketingMarketing

Manufacturing Modules (Cont)

Define Daily, Monthly or Annual Production Plans

Carry out BOM explosion for the production plan

Generate Materials Requirement Plan based on Production Plan

Generate MRP Plan on Daily, Weekly or user defined period basis

Create purchase requisitions based on MRP Plan

Material Requirement Planning

Manage Vendor database Create vendor-item catalog Send request for quotation to

vendors Enter quotations received and

perform comparative analysis Approve quotations for purchases Create purchase orders online based

on requisitions as well as MRP Plan

Purchasing

Create delivery schedule releases and send to vendors

Reschedule deliveries Create P.O. amendments Vendor performance ratingbased on

quality and delivery Fully integrated with Accounts

Payable

Purchasing

Define Multiple stores Enter all stores transactions online Stores transaction include

- Goods receipts from suppliers- Returns to suppliers- Issue to Production- Issue to others- Finished Goods receipts from

production

Inventory Control

- Returns from customers- Inter-store transfers- Other misc. transactions

Update stock transactions online to stock ledger

Generate stock ledgers & statements Update overhead costs on receipts Value inventory based on several methods -

FIFO, Standard Rate, Weighted Average Rate

Create various analysis reports (ABC, XYZ, FSN)

Inventory Control

Define QC specifications (including assay, Loss on Drying and standard test procedures for each item

Access G.R.N.’s awaiting QC online Allot testing to analysts based on

work load Generate QC register for

items/batches to be analyzed Update test results online and

match with standards to approve or reject material

Print Test Certificates

Quality Control

Define Production facilities in terms of production centers, production stages etc.

Define manpower assigned for each production stage/machine

For each product, define Process Billincluding sequence of manufacturing operation machines used for each operation

Process Modelling

inputs, outputs, yield, time, and manpower for each operation

measurements required to be taken test requirements standard operating procedures

Process Modelling

Create Production Plan based on Distribution Plan

Project gross raw material requirement

Assess plan feasibility with respect to capacity and manpower currently deployed

Analyze capacity utilization w.r.t. Plan

Analyse manpower utilisation w.r.t. Plan

Track Plan vs. Actuals Position Automatically roll over unrealized

Plan

Production Planning

Create New Production/Batch Order Generate Stores Requisition for raw

material for batch order Enter Batch Details (Operation

wise) Access Process Bills Details

including Standard Operating Procedures on-line

Generate intimations for Q.C. for testing intermediate and finished goods

Production Management

Print Batch Tickets for completed Orders

Generate- Various Production Reports- Capacity Utilization Reports- Manpower Utilization Reports- Yield Variance Reports- Batch Costing Reports- W.I.P. Reports

Production Management

Group products by product groups for planning, reporting and analysis

Group marketing areas by Zone, Regions and Territories

Define Depot wise Sales Forecast Create Depot Distribution Plans

based on sales forecast and inventories held

Create Depot despatch schedules from Distribution Plan and Production Plan

Distribution Planning

Marketing & Sales Maintain comprehensive

customer’s information Process request for quotations and

generate quotations Process Sales orders Create sales invoices, depot stock

transfer notes Track Daily Stock and Sales Fully integrated with Accounts

Receivables

Exports Management Maintain Standard Input/Output

Norms Process export licenses such as

DEPB, DFRC, Advance License etc. Generate complete pre-shipment

and post-shipment export documentation