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Process Production module typically is used for item produced where there is only one raw material item as input and as the result of various manufacturing process the final finished goods is produced. 

e.g. manufacturing industrial flange, valves body, CNC machine production, etc.

      

Key procedures are as follows:

1.       BOM masters

2.       Work Order

3.       Production Planning

4.       Production Entry

5.       Stage Wise Inspection 

 

Production Module

And Subcontractor module (Outsourcing / Third Party Job work)

 1.      Purpose:

1.1.           To automatically prepare reports based on the production related information such as raw material consumption and the factory made item that is produced at the end of production process.

1.2.           Keep location wise track of inventory including Work In Process (WIP).

2.      Modus-operandi:

Whenever any item changes its shape or size as a result of production process an entry in ERP is required.  The item that is produced is called the ‘Father item’.  The raw material from which the father item is made is called the ‘Child item’.  The relation between the father and child is defined in the ERP BOMMaster.  For example, let us say there are two raw materials A and B that produces C.  Item A and B are consumed and C is produced at the end of the production entry.

3.      Location concept:

3.1.       ERP keeps track of material location wise.  Three main locations are defined. 

3.1.1.     Hold location: Where the material is first received by the stores.

3.1.2.     Stores location: Where the raw material is moved after Quality Check.

3.1.3.     Shop floor location (Work In Process or WIP): Where the production takes place.

3.1.4.     Finished Goods store: Where the FG item is kept for final shipping.  The sales invoice is made from this FG location.

3.1.5.     Rejection Location: Where the rejected material is kept.

4.      There are times when the production takes place at the TP’s factory, also called third party (TP).  In this case we need to define the TP location in ERP and transfer our raw material to that location.  The item (may be finished or semi-finished) is received back from the TP location.  It is important to keep track of the material lying at the TP location.

5.      Sale Order (projection) link to Work Order.  ERP can link the ORI(Sales Order and Sales Indent or Sales schedule) with the Work Order (or Job card). 

6.      Prerequisites: Define item category and subcategory.  Prepare the Item Master database.  Prepare BOM master.  Prepare TP master in address database. 

7.      ERP Procedure:

Step #          Task

7.1.           Prepare Job order (Labor POfor own shop floor or for the Third Party).  In case it is in-house production in labor PO rate is not mandatory.  However, in case of outsourcing ‘labor rate’ is required.  The rate to be paid to the subcontractor.  Here the item that is produced may be sub-assembly, semi-finished goods, or Finished Goods.  BOMis mandatory.

7.2.           ERP will automatically prepare Work Order for the Item mentioned in the Labor PO.  This also gives raw material or child items (RM / PM) required as per BOM, to produce the father item mentioned in the Job order (labor PO).

7.3.           Work Order also checks the stock position of the item to be sent for production (or processing) to the shop floor location (third party or own shop floor).

7.4.           User (Stores) will enter 57 F4 in ERP for the RM / PM, which are to be transferred to shop floor or TP location as per the Work Order.

7.5.           User (Production person) will enter the Production Entry in ERP for the item produced and the quantity produced.  This will automatically consume the raw material (child items).

7.6.           Receiving the production:

7.6.1.     In case own shop floor enter the STC to transfer the material from shop floor to FG stores.

7.6.2.     Or in case of subcontracting, enter Goods Inward Note (GIN) for the item received from TP.  (Also called labor PV).  Here as per the rate credit is given to the (TP)

7.7.           User can check the stock position of the item in stores or at TP location any time before or after receiving the production. 

7.8.           Print OLP of all above transactions.  (OnLine Printing of all transactions).

7.9.           Print relevant registers.

7.10.       During implementation stage verify above ERP business processes with legacy business processes.

7.11.       Certify and keep hardcopy in a physical file until all the steps are understood by all key people.  Later use the softcopy (vies on monitor screen).  Keep printing to minimum.

7.12.       It is observed that 80% of ERP is used (core logic) as it is in any organization whereas 20% is customized.  Where as in case of Production Module it may be other way round.  We need to customize production business processes as per users requirement.  However, some BPR(Business process Reengineering) is recommended.

 

1.1.          Production Master

The following menus appear under Masters - Other Masters menu:

1.1.1.   Machine Master 

    Shift A, B or C (Shift 1, Shift 2)

1.1.2.   Operator Master

 Production module depends on the Inventory module; therefore relevant major masters are repeated here:

Item Master

Item subcategory Master

UOM  Master (under inventory master)

1.2.          Production Transactions

User can define the process flow in the item master if the same is fix or use can select process at the time of planning.

 

1.2.1.   Work Order

Work Order is a passive document, which is a communication between marketing and production.  Work Order does not change the inventory.  Work order is prepared for the item to be produced (may be finished goods or semi-finished item).  WO will also give raw material (child items) required to produce the father item.  It is compulsory to prepare the BOM.  Without work order, production entry cannot be entered.

 

1.2.2.   Production Planning

When the work order will be prepared then the production person will do the daily planning according to machines that are available to him and according to work order quantity and the process that has to be done.

The steps are as follows:

1.      First click on new button at the right side corner.

2.      Then select the work order number for which the planning is to be done.

3.      When you select the work order number, item code and work order quantity gets defaulted automatically.

4.      Then select machine name for the respective process that has to be done.

5.      In the process drop down the process defined in the work order which are required will get defaulted. The user has to select process one by one and then define its plan quantity and shift and click on add button. This procedure has to be done for each process.

1.2.3.   Production Entry

 Production entry can be done only if Work Order is prepared.

1.      This is an active document.  This will reduce the Raw Material / Packing Material from the consumed location and add item being produced (may be father item or FG) in the produced location.

1)     Pending Work Order will be defaulted.

2)     User will select the Work Order Number.

3)     Work Order will be defaulted.

4)     User has to select the Production Planning number

(PPC No) from the drop down list

5)     For example, the coilingprocess will get defaulted. The user has to insert the quantity actually produced.

6)     The user has to insert the time required for manufacturing that item i.e. start time & end time.

7)     The total quantity produced goes in the next stage.

8)     The further process should be done in stage wise inspection. 

Note: FromRaw Material required quantity will default automatically from the BOM master.

                   The work order will not get closed at the

production entry done for coiling.  All the processes are done and after

final process the work order will get closed.

1.2.4.   Stage Wise Inspection

 Stage wise inspection transaction will help to transfer the material from one process to another process.  Simultaneously it will ask for accepted quantity and then only it will show in next production process, e.g. coiling process.

The steps are as follows: 

1.      First select the WO no

2.      Then select the PPC no

3.      The process will get defaulted as shown below.  Here the coiling is done so it will automatically show that it will be transferred from coiling location to Tempering location.

4.      At the same time, it shows the previous stage quantity (see the screen dump).  The user has to enter the accepted quantity and click on add button.

5.      Then save the document.  Next time when you open the same document then it will show that in tempering the quantity is been added and take next stage of hooking.

6.      Put accepted tempering quantity and then only it will go to next location of hooking. 

 

 

As you start going to next stage, ERP will start showing the status as shown below

 

 1.2.5.   Production Reports

 

1.2.6.   PRODUCTION INDENT CONCEPT

 1.2.7.   Work Order  Register

 Shows list of Work Order for a given period.

1.2.8.   Production Register

List of production entries

MRP MODULE

Material Requirement Planning:  MRP report gives the quantity required of raw material or bought out items to fulfill a given ORI (Order Receipt Information).

1.2.10.                       Production Indent

Production indent report gives the F. G. quantity to be produced.  This is used to prepare the Work Order for production. 

14.3.8.           Production Stage Wise Report

In this report it will give all the details how a WO has gone through different stages. It will give respective information as WO no, WO date, what process done, on which machine, how much produced, in what shift and total produced.


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