ERP-Production Module

ERP• Single window solution of enterprise where in each and every

sections / departments and locations are integrated in to one. • Information flows from one place to another automatically with

no repetition of entry. • Based on ISO guidelines therefore it automates business

process in a more systematic way and help enterprise to achieve various level of standards in quality.

Integrated solution

PRODUCTION Module

• Designed for specific needs of manufacture industries include core capabilities.

• Facilitates production planning , Taking orders and delivering products to customers.

Production Module Features• Process definition with inputs, outputs, by-products and overheads• Definition of Bill of Material(BOM) for all products up to any number of

levels• Planning based on customer wise production advice and sales forecast• Material requirement planning: MRP based on machine capacity and

availability, machine efficiency, raw material availability, lead time - giving feasible quantity for production.

• Production plan for machines with optimum utilization of all available resources like raw materials and machines

Production Module Features (Contd..)• Production plan for machines with optimum utilization of all

available resources like raw materials and machines• Option to revoke production plan to change input parameters/

production priority/ quantity using fresh production advice• Generation of production schedule for machines detailing inputs

and output• Reserving quantity for production• Automatic generation of job orders for production• Option to make daily plans for production

6

The sub modules of Production• Production Control• Requirements Planning• Capacity Planning• Preventative Maintenance• Structures and Routings• Cost Control• Time and Attendance• Quality Control• Job Costing• Service and Repair• Engineering Project Management

Characteristics of Production Module• Production Planning helps an organization plan production with the optimum utilization

of all available resources.

• Material Requirement Planning is done based on the production advice generated by the sales department.

• Feasibility of production is evaluated using details like raw material availability and procurement time, machine availability and capacity.

• A production schedule is generated for all machines where the scheduling is done in an optimized fashion based on the priorities of production.

PLANNING

MODULE

Case Study of Production Module• SAP• Visual GEMS• APPS

11

Production planning module

SAP Modules

SAP R/3SAP R/3

FIFI

WFWF

PSPSPMPM

WMWM

PPPPMMMM

SDSD

HRHR

AMAMCOCO

QMQM

PP – Production Planning

WM – Warehouse Management

PM – Plant Maintenance

AM – Asset Management

PS – Project System

MM – Materials Management

SD – Sales and Distribution

QM – Quality Management

WF – Workflow

HR – Human Resources

CO – Controlling

FI – Financial Accounting

http://www.sap-erp.com/general/introduction-to-sap-pp.htm

• To plan and control the manufacturing activities• Key elements

• Bill of Material (BOM)• Routings• Work Centers• Sales and Operations planning (SOP)• Master Production Scheduling (MPS) – Capacity Planning• Materials Requirement Planning (MRP)• Shop Floor Control (SFC)• Production orders• Product costing, activity-based costing• Work in process • Kanban• Production planning for process industries (PP-PI)• Repetitive Manufacturing

Production Planning Module

FIFI COCO HRHRCostaccounting

Financialaccounting

Humanresources

ProjectNetworks

MaintenanceRepairsPlant maintenance

Inbound Raw Material

Finished Goods

•Sales and Operations Planning•Demand management •MRP•Detailed Scheduling & Planning•Capacity planning•Shop floor control•Costing•Information system

PurchasingWarehouseInvoice verification

SalesShippingBilling

CustomersCustomers

VendorsVendors

SDSDPPPP

SDSDSDSD

SDSDMMMM SDSDQMQM

SDSDPMPM

SDSDPSPS

SAP-Production Planning

18

Visual GEMS

Visual GEMS -Production Management• Production planning

– Defining Factory Capacity based on Standard (Basic) style.– Allocating Orders to factories based on criteria such as no

of machines, daily output or production span. – Graphical Order Allocation Chart for monitoring

allocations.• Generation of Production Orders • Tracking of Orders.

19

Visual GEMS -INPUT DATA

• Production Order \ Job Work Order requisitions• Periodic Production Monitoring Reports • Job Work reconciliation report from job worker• Processing Order requisition (rough processing Order)

20

Visual GEMS-OUTPUT DATA

Documents• Production Orders• Processing Orders• Cutting Requisition• Trim requisition

Reports• Production Order Status

– Order Wise– Operation Wise– Monitoring Monthly

• Order Register• Order Follow Up• Issue Consolidation Report -

Cutting / Trims

21

22

START

IE GIVES THE PRODUCTION PLAN

Production Manager reviews the Production Plan

Production Department receives materials from the Inventory

INVENTORY DEPARTMENT

SPREADING

CUTTING

Patterns from Pattern Making Department

CONTINUED

PRODUCTION MANAGEMENT MODULE

23

CONTINUED

Cut Pieces instantly moved to Sewing Line

Cut Pieces Transported to Assembly Line

Line Balancing

Assembly Line

Inspection

Kept for Inventory WIP

YES

NO

CONTINUED

24

CONTINUED

Matches with Fixed

Standard?

Final output sent to Finishing Department

MODIFICATION

END

Defect can be modified?

Reject the Piece

YESYES

NO NO

25

Export Order EntryStyle Data Bank/DispatchFabric WorkingYarn WorkingSample Approval Measurement ChartsCosting TemplateEO Closure / Locking

Accessory StockFabric StockYarn StockGarments Stock

Opening StockGate PassIssue Control Centre

Production PlanningProduction OrdersProcessing Orders

Production MonitoringProduction Reconciliation

Import Monitoring Data

Order Closure

Purchase Order For #  Fabric#  Accessory#  Yarn#  Garment

Order Closure

Import L/CImport Bill entry

Import L/C RegisterBack To Back L/C

PO Without L/C Import Bill tracking

Export LCQuotaExport Incentives (DBK)

Pre-shipment Invoice Packing List

Commercial InvoiceDraft / Bill of exchange

Bank certificate 

Click on the above Module Names to see screen forms) 

Export Orders

Purchase Orders

Production

Export DocumentationImport

Inventory

26

27

APPS 8i ERP(Apparel-specific ERP Software)

28

29

30

31

APPS PRODUCTION PLANING & CONTROL MODULE• Production Process Planning• Production PO Generation• Lot Cut Plan Creation• Daily Cutting Tracking• Production Issue & Received Follow up• Finished Goods Received Tracking• WIP Transfer• Daily Production Report Generation• Production Summary Generation• Vendor Payment Tally Sheet Generation

32

APPS 8i -Features• Efficiency Planning• Unit Resource Planning• Machine Planning• Target Setting• Master Plan generation• Production Plan Report• Machine Allocation status• Daily Plan details• Order Plan details• Planned Vs. Actual

33

Thank You!!!

34