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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