EMpro - A Manufacturing ERP

SEI CMM Level 5 Company

MIND

BY

MothersonSumi INfotech & Designs Ltd.

C 26, Sector 62, NOIDA, India

eMPro Business Suite


eMPro is web based end-to-end business solution,designed to handle Industrial Trading, Discrete,Assembly/Metal Processing, Automobile Tier Oneand Tier Two Industry, business needs in areas ofProduct Design, Planning, Inventory, SupplyChain, Manufacturing and Finance.

What is eMPro ?

eMPro has inbuilt integration with most of the Automobiles OEMsin India to reduce supply chain cycle time.


Multi Database

Pluggable Modules

Web Enabled

Seamless Integration

Audit TrailMulti Currency

Flexi Charging Module

Work Flow Base

Multi Plant

Multi UOM

Key Features


eMPro Functional Flow

Integration with Customer Schedule: EDI Manual Data Upload

Rough-cut Capacity Check Shop Floor Capacity Planning

Master Production Scheduling Shop Floor Loading Plan Work Order Generation

Material Planning Material Shortage Ordering Suggestions Material Transit tracking Integration with vendors

4

Gate Entry Incoming Checks Incoming Inspection Inspection Results Capturing Accounts Payable TaxationLanding Cost CalculationsBarcode Enablement

Raw Material / Bought out Item StocksMaterial Requisition SlipMaterial IssuanceMaterial MovementJob Work ManagementPhysical Inventory CountsInventory Valuations

Finish Goods Stocks Shipments EDI Enablement Dispatch Advice Barcode Enablement Invoice Advance Shipment Notification Accounts Receivables

CUSTOMER DEMAND FULFILLMENT PROCESS

WO

RK

FL

OW

SY

ST

EM

-E

AS

Y

Sales Portal, Vendor Portal FINANCIALS: Fixed Assets, Budgeting, Project Accounting

Quotation Management

Vendor Development

Order Management

Documents

Scheduling

Production ControlCapacity Check

3 2

Customer

1

Supplier

CustomerSupplier

Daily

Primary and Secondary Production Process

In-Process Inspection

Shipping

Daily

5 6 8

Change Management

Product Development Bill of Resources

Business Forecast

Order Generation

Order Management

Receiving

Production Control Production Result Capturing Efficiency / Utilization / OEE Lot & Batch Control WIP Tracking Barcode Enablement Machine Maintenance

7

Stocks Management


eMPro Finance Function Flow

Budget Definitions at GL, Project, Cost Centre LevelBudget Vs Actual Reporting

Project capturing at each transaction Level

Customer

General Ledger

General ledger Journal Voucher Employee, Project and Cost Centre Books Trial Balance, Balance Sheet, Profit and Loss

Bank and Cash Payments /Receipts Bank Reconciliations

Project Accounting General Ledger Budgeting

ePay HR App (Salary Posting)

FA Management Depreciations FA Registers

Recoverable Tax Claim Purchase Voucher Generations Debit / Credit Notes Payment Holding Vendor Ageing and control

Sales Voucher Debit Credit Notes Customer Ageing

Fixed Assets

Weighted Average Valuations FIFO Valuations

RM Inventory WIP Finish Goods Inventory Shipments Invoice

Material Receipts

Accounts PayableAccounts Receivables

Bank & Cash

Valuations

Raw Material Stores Production Finish Goods Warehouse ShippingSupplier Receiving


eMPro Integrated Overview

EDI, File Upload on portals,

Extranet Labels, Dispatch

Documents

EDI, Specific File Uploads

Third Party Financial Software

HR Applications

Third Party Manufacturing Application

Integration with Supplier

Integration with Customer

Barcode RFID

Integration with Design Solutions

Finance

Purchase

ManufacturingStores

Sales

Engineering

Shop Floor Machines


eMPro - Logical Architecture

PRESENTATION LAYER

UI Components Active X Ajax

BUSINESS LOGIC LAYERBusiness Components .NET Class Library

DATA ACCESS LAYERData Access Components ADO.NETS

EC

UR

ITY

Database

Global Components

Module Specific Components


eMPro - Physical Architecture

Internal user

Client Browser

Application Server 1

Database Server

External User

Web Browser

Report Database Server

Can be one server also for small implementation

InternetApplication Server 2

Application Server n

Finance

Engineering

Material


Multitenancy Architecture

Customer 1http://mindeservices/empro/abc

Dat

abas

eA

pp

licat

ion

Separate database for each hosted customer

Customer 2http://mindeservices/empro/def

Customer 3http://mindeservices/empro/ghi

Customer 4http://mindeservices/empro/jkl

Internet


Results

Customer Details

Background Modules Overview

1. Implementation effect

Company being primarily into industrial Trading Business Work on Sales engineer network responsible for sales .

Major Concerns being-

a) Stocks Control,

b) Credit Control ( Payment default)

c) Wrong Dispatches to customer

d) Finance working in isolation

e) High rate of sales return

Sales Module OGP)

Purchase ( VDP)

Inventory( OFP)

Finance

1. Debtor Control up by 100%. Payment default reduced by 90 %

2. Stock gap between physical and actual reduced to 99%.

3. Sales return reduced by 80%

4. Wrong dispatches reduced by 95%

5. Finance control automatically better now with each entry being linked to finance

Primarily into Sheet Metal Component manufacturing

Major Concerns-

a) Job work item material reconciliation with vendor

b) Scrap management

c) Finance control and statutory reports requirement

Sales Module (OGP)

Purchase ( VDP)

Inventory( OFP)

Finance

1. Job material work reconciliation 90%

2. Scrap generation & control up by 98%

3. Finance control complete , all statutory report going 100% thru system.

4. Delay in Monthly account closure reduced by 100%. Monthly books closed by 7th of each month.

Primarily an OEM , Compressor manufacturing

Major Concerns-

a) Third party Job work items

b) Stocks Tracking

Sales Module (OGP)

Purchase ( VDP)

Inventory( OFP)

Finance

1. Third party Job work Item material reconciliation increased by 89%

2. Stock gap between physical and actual reduced to 99.3%.


eMPro Valued Users

200+ Plants in India, Mid East, Thailand, Mexico and Europe 5000+ Users 250 million+ transactions in last financial year

Hi-lex India Pvt Ltd Manesar

Mehra Metal Components - Ballabgarg

Arvicon Exports - Delhi

30+ Plants on one Server, with 2000+ Users doing 130 million+ transactions in one financial year.DB 2.3 TB +


Modules Details


Product Development

Item Masters User Defined / Guided Item code generation

Multi Level Bill of Material (BOM)

Formulation master & release

Subcontracted BOM s

Handling of Multiple BOM s for one Product

Manufacturing behavior (Subcontracted, Purchase, Manufactured) and BOM mapping according to unit in Multi unit environment

Process Sheet Printing for Shop for instructions

Follows complete Product Life Cycle

Development, Manufacturing, Obsolete

Product History Reports

Where Used Query

Engineering reports

Multi Level BOM

Alternate BOM

Route Definition and Process Sheet Definition

Engineering BOM to Manufacturing BOM

Product Life cycle

Where used Query

Customer Model Matrix, multiple vendor share.


Sales

Pre- Sales Process of Enquiry / Quotation

Customer Order Management and Amendment history

Customer Schedule and Dispatch Plan

Invoicing & Dispatch barcode / mobile devices

Scheduled Dispatch Document preparation without human intervention.

Invoice Removal / Gate pass

Trading Invoice (Online purchase document Reconciliation), Retail Invoicing

Supplementary Invoices ( Auto and Ad hoc)

Customer & Transporter Acceptance

Sale Rejections , Rework & Returns

Integration with Customer Database, communications and EDI systems

Sales Person / Manager / Region / Item wise Sales Reporting and Sales Analysis

Bar-coded Dispatch Documents (customized)

Export Invoicing

Performa and Supplementary Invoicing.

Tracking and Reconciliation of customer Supplied Items and reusable packing material.

Reconciliation of Input Items in Job working Sales Orders

Customer sales forecast - model wise, part wise, flexible business period

Customer Enquiry

Quotation

Customer Order / Open Orders

Customer Credit Control

Schedule Tracking / Model, Product wise dispatch plan.

Customer Dispatch Tracking thru mobile / barcode devices

Customer Supplied item Tracking

Trading Item Reconciliation

Integration with Customer system

Region wise/Sales Engineer wise /Item wise Sales Tracking


Purchase

Purchase Indent

Purchase Order Processing multi type, multi series

Vendor Quotation management

Value Base Purchase Order Approvals

Order Amendment history

Job work BOM definition with PO

Tool Amortization definition in PO

Vendor Delivery Schedules

Direct Delivery Schedules to contractual vendors

PO and DS direct to vendor thru mails

Integration with Vendor Database - For PO and DS transfer

Purchase Analysis

Project Tracking from Purchase Indent to PO to Receipt to Finance.

Purchase Indent Tracking with Value based approval

Vendor Quotation Management

Vendor Order and Schedule tracking

Vendor performance Tracking

Sub Contracted Purchase Order process


Procurement

Gate Entries

Stores Material Receipt Multi type, multi series

Integration with vendor system for dispatch data transfer

Incoming material tracking -thru mobile / barcode devices

Excess and Short material tracking

Inward Quality Control and Quality standards

Supplier approval, Self Certification process, Revalidation process.

Inspection Result Recording

Quality Problem Reporting and Response.

Job work- Input Material Reconciliation and set wise Material Tracking

Inspection Analysis

Vendor Rejection Management

Receipt Analysis and Reporting

Purchase Price Variance

Material Receiving Process - thru mobile / barcode devices

Incoming Inspection process

Vendor Rejection Process

Excess material receive tracking

Integration with Vendor System


Inventory Setup multi locations in Units with standard behavior

Lot Control

Material Request

For Internal Manufacturing, Job worker, Stock Transfer as per production plan , adhoc

Material Issuance Material Request, as per production plan, adhoc.

Material Issuance Picking thru barcode RF devices, FIFO Control (customized)

Excess Issues Tracking

Material Return

Material Movement with Job worker

Material Request, as per production plan, adhoc

External Material movement document

RGP / NRGP / Stock Transfer Notes etc

Inventory Movement Tracking

Physical Inventory/Cycle Count/ Stock Adjustments

Inventory Accounting and Transaction Reports

Inventory Analysis and Inventory Aging

Inventory Valuations FIFO, Weighted Average, User Defined multiple fix cost sets.

Inventory Balance / valuation as on date, multiunit, multi locations

Inventories

Multi Location

Material Request and Issuance

Internal, Sub Contractor ,Multi Units Stock

Transfer

Set wise issuance

Lot Control (with Bar Code / RFID Solutions)

Inventory Transaction

Excess Material Tracking

Physical Inventory Process

Inventory Valuation


Manufacturing Master Production Schedule

Shop Floor Control Plan (SFCP, Auto Child SCFP generation, for multi level BOM )

Material Requisition As per SFCP, Ad hoc

Production recording Back Flush

Operation wise

Machine wise

Machine Group / Machine Definition

Operation, Tool & Route definition ( As per Production process)

Idle Machine hours/ Machine down time tracking

Machine / Operator Utilization and efficiency .

Shop Floor Control Plan (SFCP) tracking

Premature closing of SFCP s

SFCP Ageing Analysis for better Management control.

Line Rejection Note

WIP Balance As on date, multi units, multi locations

Material Request for movement to Bonded store

Material Movement to Bonded Store thru RF Base barcode devices. (customized)

Master Production Schedule

Shop Floor Control Plan Tracking ( Work Order)

Route Base Production recording - thru mobile / barcode devices

Item /Machine /Tool wise Production Tracking

Machine/Operator Utilization and efficiency

Online WIP Balance

Line Rejection


Material Requirement Planning

Suggest Vendor Orders with Vendor, Item, Quantity, Date and PO.Reduction in Ordering Cycle Test Run in 10 Minutes 100 Finish Products, 3 Months MPS and

Ordering Period, Average BOM - 20 Raw Materials

Gross Material Planning Flexible Periods Safety Stock Fix , As per Consumption , Both Projected Stock Open Orders Vendor Shares Pack / Lot Size Required / Ship Date Calculation Vendor Schedules Analysis Sheets - Calculation Backup

Reduction in Ordering Cycle

Vendor Share and Priority markings

Vendor MOQ and PPQ definition

Material In Transit

Safety stock (Fix and Consumption basis )

Vendor PO and Schedule Suggestion

MRP cracker ( Calculation Breakup)


Production Requirement Planning

Production Requirement based on customer sales schedule, Stock- in-hand, Rejection allowance and current OEE.

Net production Requirement considering Current shipment, Back log & Total safety stock or as defined parameter

Line, Machine , Tool and Route Definition

Capacity Requirement Calculation on basis required days for production as per defined the process lead time of respective rout. Available M/c/Tool days & working days

Master Production Schedule (MPS) date & shift wise. Planned considering , safety stock, buffer days & cushion of the respective product as provided in the production coverage report (PCR)

Unplanned Item Listing

Provision For Family Tool case

Conversion of Master Production Schedule to Shop Floor Control No ( Work Order)

Day wise /Shift wise SFCP Generation

Line wise / Machine wise / Tool wise Day Loading

Planned VS Actual Production tracking

Production Requirement

Capacity Requirement

Master Production Schedule Suggestion

Unplanned Item details

Daily Line/ Machine /Tool load details

SFCP generation from Master Production Schedule

Planned Vs Actual Tracking


Distributed Approach

Accounts Payable, Accounts Receivables, Treasury, General Ledger

Five Level Account on each transactions - Ledger, Sub Ledger, Cost Center, Employee and Project

Auto and Recurring Activities for Productivity Improvements Templates for later posting, Payments, AP Vouchers, Debit / Credit Notes, Journal Vouchers

Inter Unit Support Auto Inter Unit voucher generation Payments, Receipts, DR/CR Notes

Auto Reconciliations Bank, Inter Unit, Customer / Vendor )

Control Account mapping - AR, AP and Treasury, Taxation and Inventory

Project wise - P&L statements. Specific Project expense booking and Common GL(expense) allocation on pre defined methods.

GL Payable Tracking

Handling of Excise, Service Tax and Sales tax returns

Generation of TDS Challan /returns and Form 16

User-Defined Business Periods

Unit Specific configurable GLs

Finance

Account Receivables

Account Payables

Treasury (Multiple Banks)

Accounting Transaction 5 levels

Ledger , Sub ledger , Project , Cost Center, Employee

Auto and recurring vouchers

Advance Tracking

Outstanding Analysis

Financial Year closing vouchers

Multiunit consolidated finance reporting

Project Accounting

Indian Statuary handling

Trial Balance, P&L Statement, Balance Sheet


Multiple Groups / Multi Companies with Multi Locations Handling

Maintains History of all changes

Automatic Email of Pay slips at individuals Email Ids

Attach Scanned Pictures / Documents to an Employee

User Defined Salary Components

User Defined Dynamic Salary Formulas

Approval Process

Musterroll

Employee Detail Forms & Reports

Dynamic MS Word reports

Bank Transfer Reports

ESI and PF Reports

PF Challan, PF Statement, Form 12A, Form 3A,

Form 5, Form 6, Form 6A, Form 7 and Form 10

Income Tax reports

Form 16, Form 12BA and Tax Projection Report

Bonus Report Form C and Annual Salary

Loan and Attendance Ledger

Integration with attendance devices

Cash Payment of Salary, Bonus and Over Time Payments tracking.

ePay Payroll System (add on system)

Employee Details Management

Attendance Management

Loan and Advances Management

Arrear (Leave & Salary) Calculation

Salary Processing and Approval

Over Time Process

Reimbursements Details

Bonus Payments

Full and Final Process

Income Tax Calculations

Salary Voucher Posting to Finance

Statutory Reports


Thank you

MothersonSumi INfotech & Designs LimitedC-26, Sector-62, Noida 201 309

(INDIA)Website: www.mind-infotech.com

Aseem Gupta [email protected]

We look forward to a long term business partnership built on trust & mutual cooperation

EMpro - A Manufacturing ERP

Documents

Transcript of EMpro - A Manufacturing ERP