erp -production module
DESCRIPTION
ERP SYSTEMS USED IN APPAREL PRODUCTION (FOR PRODUCTION DEPT)TRANSCRIPT
ERP-Production Module
Presented By:Amalesh Deka
Ankita Gupta
Anoop Singh
Anshita
Arpita PandaAP-VII, NIFT-Bengaluru
Presented To: Ms. Sudha Singh
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
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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
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
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Case Study of Production Module• SAP• Visual GEMS• APPS• PROMAN 3.0
Production planning module
SAP Modules
SAP R/3
FI
WF
PS
PM
WM
PP
MM
SD
HR
AM
CO
QM
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
• 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
FI CO HRCostaccounting
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
Customers
Vendors
SDPP
SDSD
SDMM SDQM
SDPM
SDPS
SAP-Production Planning
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Visual GEMS
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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.
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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)
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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
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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
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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
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CONTINUED
Matches with Fixed
Standard?
Final output sent to Finishing Department
MODIFICATION
END
Defect can be modified?
Reject the Piece
YESYES
NO NO
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Export Order EntryStyle Data Bank/DispatchFabric WorkingYarn WorkingSample Approval Measurement Charts
Costing 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
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APPS 8i ERP(Apparel-specific ERP Software)
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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
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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
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PROMAN 3.0
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PROCESS FLOW
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PROMAN 3.0• PROMAN is a production management software which monitors all activities on the
shop floor from time study and production planning till the garment is finished and packed.
It smoothly integrates all the operations in a garment factory and generates very useful MIS reports to remove bottlenecks and improve productivity.
This can also seamlessly integrate with STAGE or work independently.
PROMAN improves profitability, reduces production costs, improves product quality.
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PROMAN 3.0• PROAMN identifies bottlenecks in the Production Line and alerts the line supervisor so that
the problem can be addressed and production in the line can be balanced.
• Work In Progress at each location can be generated
• Option to plan capacities with learning curves.Automatic MIS Report Generation can save a lot of time for users by avoiding manual / spreadsheet reports.
• PROMAN also has the option to track daily production using bundles tickets with barcode.
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REPORTS• Factory Production Report• Bottleneck Report• WIP Report• Machine Deployment Analysis• PPDPM Report (Graph and Data)• Day wise Factory Summary• Bundle Tracking Report• Production Summary Department wise• Daily Production Summary Factory wise• Line wise daily Production ReportDaily • Finishing ReportSkill Assessment Report• Daily Cutting Report• Incentive Statement Report
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PROMAN 3.0• P.O. Status Report• Piece Rate Report• Factory Efficiency Report• End batch, Finishing & AQL Reports• Employee Efficiency Range Report• Finishing & Packing Reports• End bit Stock Report• Machine and Spare Parts Inventory Reports
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PRODUCTION PLANNING• Product structure, dependent relationships and ECO functions are
all fully integrated with scheduling, manufacturing routings, capacity planning and MRP. PRO:MAN delivers maximum visibility into inventory and capacity requirements.
• Bills of Material• Master Scheduling• Material Requirements Planning• Capacity Planning and Routing
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Thank You!!!