The basis for sound profitability in a manufacturing company is the ability to manage raw materials and resources from order to the delivery of a flawless product, as quickly, inexpensively and smoothly as possible. If this is to work in the long term, it needs the support of an information system that can be developed at the same pace as the company and the world around it changes.
This is the foundation on which Vision Manufacturing rests. Clear and simple flows are provided for routine issues, with advanced functionality to support exceptions. A powerful, multifaceted solution, it supports analysis and control in all types of manufacturing, in all phases of the manufacturing process, and for all employees in the organization.
Vision supports both make-to-order and make-to-stock modes of manufacturing. In make-to-order, the order is broken down directly to manufacturing orders at optimal levels, without going through MRP. Before an order is released, the material can be reserved and issued. The production status is updated continuously with the help of production reports, making it possible to re-schedule to gain the best possible benefit. Material consumed and operations performed are reported, forming the basis for cost accounting. Vision Manufacturing is suited to different manufacturing organizations, providing support, for example, for decentralized organizations where groups have their own responsibility for planning.
Assemble to order provides functionality for Final Assembly Scheduling, with or without shop orders. It also gives strong support for the handling of configured end items with tight integration to the configuration .
Is a comprehensive tool that enables users to monitor and control the entire life cycle of manufacture from creation of a workorder , and schedule, through release, issue material , reserve and pick to report receive.
It is the interface between planning and shop floor , ensuring that work planned is actually performed. Its performance monitoring capability allows users to continuously track jobs and check their status. Also included are configuration management, performance metrics and cost control.
A work order authorizes the production of specific items or products and includes a list of the required components and manufacturing steps. Prior to releasing a work order, component availability can be checked and specific items or substitute items can be allocated. Labor and machine availability can be checked and alternate routings or work centers can be selected. Shop Floor Control functions are used to track the production process including labor, setup, down time, rework, and rejects. A work order may be split at any time during the process up until the finished products are received into stock and the work order is closed. All costs and variances are collected and reported by work order.
Rework, expense, and final assembly work orders
Split work orders
Manages co-products and by-products
Subcontract operations tied to purchase orders
Component availability checking prior to release of work orders
Single transaction to issue components to a work order
Detailed history maintained for all material, labor, and cost transactions
The Shop Floor Control module tracks activities and records operation status and labor times for manufacturing jobs released through the Work Orders module. Shop Floor Control uses the work order routing to calculate usage variances, efficiencies, and utilization. Rate, usage, and method variances for both labor and burden are calculated at the time labor is reported and may be posted immediately or held until the work order receipt is processed.
– Labor reporting by order, employee, or work center
– Automatic move to next operation
– Quality test results prompted for selected operations
– Subcontract purchase order receipts create operation history
– Costs posted to the general ledger (GL)
– Labor reports include shift, department, machine, and pay rate
– Efficiency reports by employee, work center/machine, or work order
– Input/output inquiry and report to show planned and actual queue, and input and output hours by work center/machine
– Scrap reporting
– Full audit trail of all GL postings from shop floor control
The master production schedule translates the demand plan into a time phased statement of production. The MPS separates the forecast and sales demand from the material requirement planning. The MPS states what will actually be produced to meet the demand. The MPS may call for production of items during periods when demand is low and vice – versa.
Vision contains advanced functionality that supports efficient, dynamic master scheduling. The system supports simple one-level or complex multi-level master scheduling, where, for example, finished products with similar material or resource requirements can be arranged in product families. When products are manufactured from standardized modules or semi-manufactured products, however, it might be of benefit to create the forecast and master scheduling on a level below the finished product. With the help of rough-cut capacity planning against a capacity level, leveled production strategies are supported.
The system manages centralized multi-site master scheduling with the help of user-defined planning bills. The available-to-promise functionality ,together with forecast calculation, provides excellent delivery information
Quality Management incorporates comprehensive equality control information directly into the ERP database. The module is tightly integrated with the entire production execution process. It provides for traceability through the supply chain From raw materials through the procurement , production execution to the finished product.
Quality orders are templates specifying a set of instructions and testing procedures to be carried out on each inventory part, supplier, work-center, manufacturing cell , machine and process. Quality orders are routed in a predefined path to the concerned employees or work stations ensuring control and monitoring of the quality process. The test results are recorded at each stage and are available to analyse performance of materials and machines.
Vision ensures that the “right” material ( a specific batch or lot) is issued to the shop floor . Inventory can be bar coded and scanned on issue , this is validated by the system and minimises human error.
It monitors the life cycle of tools for calibration, replacement etc and has a functionality to ensure that testing equipment and machines are calibrated as per a defined schedule. It integrates with the manufacturing planning module reflecting the non-availability of machines, tools and equipment till they have been re-calibrated and available for use
Plant Maintenance supports the plant maintenance process in its goal to reduce equipment downtime and maximize production output.
It delivers the critical functionality needed by today’s plant maintenance users on the factory floor. Vision assists in identifying appropriate maintenance procedures for your operation.