Real-Time Inventory Data, Accurate Forecasting Key Elements Aide Management Decision Making.
Real-Time Inventory Data and Batch Processing Give Management Close Expense Monitoring
The chemical industry is made of companies that are involved in the production of chemicals with high economic impact. Chemical industries involve the processing of raw materials obtained by mining and agriculture, among other supply sources, into other useful materials and substances. These chemical processes include chemical reactions to form new substances, separations based on properties such as solubility or ionic charge and distillations and transformations by heating and other methods. Low margins and high fixed costs in the industry mean that tight control and visibility to all aspects of your operations are essential to maximize your profits in a competitive environment. Optimizing manufacturing efficiency and flexibility, and improving customer relations and service, are key to your continued success, as is the management and control of hazardous materials and quality control.
- Inconsistent quality of raw materials
- Products cannot be reduced back to their original state once they are processed
- Product is normally manufactured in bulk and then packed according to requirements
- Conformance to control of hazardous materials necessitates storage of backup certificates of approval
- In a number of industries, every order represents a new product depending on the formula used and the substitutions made
Driscoll & Associates, Inc. and SYSPRO Solution:
SYSPRO’s Inventory Management module is the heart of the system bringing the sales, planning, valuation and control into this module. There are tools that will allow for analysis of inventory levels and turnover. The system is real time and will show the current items on hand, availability, usage, allocations and open replenishments. The system supports lot and serial tracking. Inventory cost can be at standard, average, last cost or FIFO / LIFO layers. The system is a true multi warehouse system with the ability to track transfers between warehouses.
Goods in Transit
SYSPRO’s system will track goods in transit, which will provide greater management control over stock items that are being transferred between warehouses. The system achieves this by monitoring warehouses transfers and supply chain transfers. Warehouse transfers are generated using the Inventory Movements program, where the transfer of an item from a source warehouse generates a detailed record of the transaction. Stock is depleted from the source warehouse at the time of confirming each line of the transfer. At the receiving warehouse, a review process with extensive selection criteria enables you to control the receipt of this stock. Supply chain transfers are generated using the S/O Entry program. The capture of a supply chain transfer order enables you to reserve stock for transfer at a later point in time (as opposed to an immediate transfer out catered for by Inventory Movements). The primary purpose of the goods in transit system is to manage the regular transfer of stock between multiple warehouses.
Purchase Orders / Blanket Purchase Orders
SYSPRO’s Blanket Purchase Order facility within the Purchase Order module allows the user to create, maintain and use contract purchase orders as well as to monitor purchase order receipts against a supplier's contract. The purpose of these contracts is to allow a fixed price to be recorded for a specified period and/or volume, plus an agreed upon delivery schedule. With extensive querying and reporting capabilities, you can centrally manage anticipated deliveries and review supplier delivery performance.
SYSPRO’s Forecasting module provides a simple, easy to use forecasting management tool. Based on the available history it suggests future stock replenishment, with the option of removing 'outliers' and enables manual adjustment to the history. Manual adjustments might be needed in terms of market intelligence or unusual demand. In addition there are reports, both tabular and graphical, in format allow for easy reference and the ability to delve into the forecast detail.
SYSPRO’s Requirements Planning module is the focus of the manufacturing and material resource planning system. The objective of requirements planning is to create realistic purchasing and production schedules, optimize stock holdings and identify capacity constraints in a multi-site, multi-warehouse environment. The module assists with the planning of materials and production capacity required to meet demand and identifies levels of usage of critical resources for rough-cut capacity planning. It allows for the easy creation of build schedules from Master Production Schedule (MPS) suggestions and the shop floor, and it suggests purchasing, production and transfer schedules to satisfy demand.
SYSPRO’s Lot Traceability module is designed to provide full traceability at transactional level for items. Companies in the following industries use this module: electronics, aeronautics, defense, food & beverage, pharmaceutical, motor vehicles and building. This module records material movement through the receiving, manufacturing, assembly, inspection, stocking, and final dispatch stages. The integration with SYSPRO's other modules permits full upward and downward traceability through all inventory transactions. The module traces product life cycle from raw materials to final products.
SYSPRO system has very strong, real-time finite capacity scheduling capability. To stay competitive, manufacturers must operate in a lean operational environment. This finite capacity capability enables manufacturers to use flexible, short-run, short-horizon scheduling resulting in cost effective jobs. Finite Capacity Scheduling creates realistic schedules and promise dates for customers, which increases profits by improving productivity and customer satisfaction, yet reducing costs.
Engineering Change Control
SYSPRO’s Engineering Change Control (ECC) enables you to improve and continue to maintain the management of engineering changes to your products. This is achieved through various features and processes - the essence of which is the Engineering Change Order process (ECO). The Engineering Change Order process is a workflow type subsystem, intended to replace the paper trail that typically accompanies any changes to product design data. When the product is under the control of ECC, any maintenance to a bill of material and/or routing of the product can be accomplished only by means of a current ECO.
Work in Progress
SYSPRO’s Work in Progress module enables you to accurately control costs of work orders currently in progress. Material usage and labor can be posted in real time and in batch mode. It also enables variance reporting to be produced between estimated costs and actual costs of each job. Work orders may be added for stocked items (with a bill of materials), stocked items without a bill of materials or non-stocked items. These work orders can create a bill of jobs for all relevant sub-assemblies down the BOM chain. Labor transactions can be posted through kit issues, manually or imported into the system from a data collection interface. Material allocations can be issued to a job through kit issues or manually and optionally allow for the substitution of a material allocation when performing kit issues.
Dangerous Goods Text
SYSPRO’s Dangerous Goods Test can be very useful in industries where customers need to be notified of potential hazardous materials. Dangerous Goods Text can be associated with the potentially hazardous Inventory items and optionally printed/attached to the Sales Order documentation.
The Backflushing function in Inventory Movements module is designed to record the manufacture of items without using a Work in Progress job. By using the manufactured item's bill of materials to determine the material and labor charges, backflushing enables you, in one process, to issue the materials from inventory, apply standard labor costs, and receive the finished good back into stock. Companies manufacturing items which use a production line to transform the raw material into a finished product in an extremely short time e.g. manufacturing electrical components, plastic ware, steel nails and fencing would typically use backflushing The integration with SYSPRO's Bill of Materials module permits full visibility through all inventory transactions.
Variable Bills of Material
SYSPRO’s Variable Bills of Material have significant variance in their products from one raw material receipt to another up to the final product. SYSPRO is flexible and can capture material variability, on a lot-by-lot basis, easily adjusting formulas and recipes while ensuring excellent overall quality. This flexibility will enable the manufacturer to use materials in the most effective manner enabling considerable cost savings
Customer Relationship Management
SYSPRO’s Customer Relationship Management (CRM) suite of applications will enable Food and Beverage manufacturers to increase revenues and client satisfaction through optimal client management. The CRM solution is designed to offer all the key components of business management in one simple module combining customer contacts, marketing, sales, customer service, Help Desk, and after market service and repairs. CRM allows everyone to share the same information putting people in the center of the enterprise with a 360 degree view of the marketing, sales, order fulfillment and accounting transactions.