Process Manufacturing

Agend
a
Challenges
 Present scenario
 Traditional vs New
Approach
 Key Drivers
 Definition
 Solution: Process-wise
 Modules
 Best Practices
 Advantage
 Customers
Challeng
esCompetitive 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
Traditional Present Approach

Exensys is sensitive to present needs

Through MPS and
MRP
Basic or no Production Planning Effective Production Planning
Through
-(CRP)Verification
Lack of Capacity Capacity CRP, RP, RCCP
MPS - Master
Requirement
Production
Planning
Absence of Inventory Planning Net Planning in MPS and MRP
Scheduling
-(RCCP) Rough-cut
Exensys’ Production
MRP – Material
Capacity Planning
Order module
Lack of Control-Shop Floor Activities Production Order
Requirements
enables Controlling
Planning
WIP can be tracked
of Shop Floor
at all
Cannot Trace WIPstages with WIP Tracking at all Stages
Activities – Efficient
the help of PAC
Processes
(Production Activity
Lack of Analysis–Production
ATP: Availability Stages
to Promise Analysis at all stages
Control)
(Customers can be
promised
Cannot Commit of delivery times
to Customers ATP & CTP
based on the Available
Inventory)
CTP: Capability to Promise
Process Manufacturing
Process Manufacturing

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

Logic: 1. Preliminary SOP is prepared

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

Output: Allocated production plan

 Process Manufacturing

SO
P MS
Manufacturi Master Scheduling
ng Cycle
Input: Firm Production Plan, Sales order
Services etc, Project, Manual etc.,

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 SOP
MS
Master Production
Manufactur Scheduling
ing Cycle Input: Approved master scheduling MPS

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
Master Production
Scheduling
Input: Approved master scheduling MP
S
Manufacturi
Logic: 1. Planning period entered
ng Cycle 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 MP
Logic: 1. Scheduling type defined S
2. Start date/end date of all
manufacturing items calculation
3. Load of work center calculated
4. RCCP quantity finalized based
on load
RCCP
5. Firm MPS quantities arrived
Manufacturi Output: Firm MPS quantities
Input to MRP
ng Cycle
Process
Manufacturing
SO
P MS
Material
Requirements
Planning
Input: Firm MPS MP
Logic: 1. BOM explosion S
2. Offsetting of MRP items
3. Net requirements calculation
4. MRP record generation
RCCP
Manufacturi Output: Input to CRP
ng Cycle Input to planned orders
for procured items

MRP
Process
Manufacturing SOP
MS
Capacity Requirements
Planning
Input: MRP firm dates for manufacturedMP
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 MPS
Input: MRP for procured items
CRP for manufactured items
Logic: 1. Confirmation of planned orders
2. Release planned orders
Output: Input to purchase indent RCCP
Input to production orders

Manufacturi
ng Cycle Planned
orders MRP
CRP
 Process
Manufacturing SO
P MS

Process Order
Manufacturi Generation/ MP
ng Cycle Release
Input: Released planned orders S
Logic: 1. Production order generation
2. Order release for all operations
3. PO items release
Process RCCP
Output: Item request to inventory
orders
Production
can
also be
Planne
generated MRP
without any d
orders CRP
planning
(manual)
 Process
Manufacturing
SOP
MS
Manufacturi
ng Cycle Shop floor Reporting
Shop floor
MPS
reporting
Input: Completed operations
Logic: 1. Material details
2. Machine details
Production 3. Quantity produced
Output: Status of production order
RCCP
orders

Production can
also be Planned
generated orders MRP
without any CRP
planning
(manual)
 Process
Manufacturing
Order
SOP
Confirmati MS
on
Production Order
Shop floor Settlement MPS
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 RCCP
orders
5 Lot Number
Production can Output: Completed production orders
also be
generated Planned
orders MRP
without any
CRP
planning
(manual)
Process Manufacturing

SOP
Order
settlemen MS
t
Input to SOP and MS
Shop floor
MPS
Manufacturi reporting Input: Backlog orders
ng Cycle Logic: 1. SOP production plan calculation
2. Master scheduling for customer
orders
Process
Output: Initiation of SOP and MS RCCP
orders
Production can
also be
generated Planned
without any orders MRP
planning CRP
(manual)
Module SO
Order
s settleme
P MS
nt

Shop
MP
floor Master
reporting Execution S
Planning
and Control
Detailed
of
of
Scheduling
Resource
Process Resources
and planning
s RCCP
orders

Planne
Manufacturi d MRP
ng Cycle orders CRP
Modul
es Manufacturing
It consists of
two sub
modules:

 Production
Planning

 Production
Activity Control
Production
Planning
Production
Activity Control
Module
s Production
Planning

Master Planning of Detailed Scheduling and

Resources Planning

• Manual Forecasting
• Preliminary Sales and •MRP Run
Operations Planning
• Resource Planning and •MRP Record
Leveling
• Production Plan Allocation •Capacity Requirement
• Master Scheduling Planning
• Master Production
Scheduling •Confirm Planned Orders
• Rough-cut Capacity Planning
•Release Planned Orders
• 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
Wood
Paints Minerals
Chemicals Paper and Pulp
Petroleum Printing
Coal Publishing
Textiles and Apparel Consumables
Metal Food, Beverages and
Tobacco
Thank you