Production Management Modules
Therefore, companies can realize a transparent, consistent, reliable and efficient production process. The production orders generated on the module include all the requirement information for the production, such as the quantity of the product to be produced, the variant, the BOM components and the route operations. During the creation of a production order, the missing material analysis is performed automatically. This module employs forward or backward scheduling, and it allows the operations to be given a new deadline accordingly with the help of detailed planning types. It is also possible to acquire information on resources and the use of resources. Another feature is to make ‘Planned’ and ‘Actualized’ comparisons for production levels, input quantities and production quantities in this module.
The process of the Production Management module is shown schematically on the graph.
PRODUCTION ORDER FEATURES AND MANAGEMENT
In the Production Management module, it is possible to perform single-level or multilevel production (that includes semi-products needed for product and production). This module allows the production of similar products to be managed with a single production order, or it can be used for disassembly production. The production plans created by the Material Requirements Planning module are not considered as (to be added here) production order. The plans created in the Material Requirements Planning module can be converted into production orders with the ‘Convert from Plan to Production Order’ feature in order to initiate them as production orders. The module can automatically convert the production plan containing the required quantities of the relevant material into the production order when needed.
During plan conversion, the values suggested by Material Requirements Planning can be used for routing purposes as well. During the creation of a production order, missing material analysis is performed automatically. In this analysis, whether the required components are present or not can be checked. The relevant parts can be automatically reserved for the required date so that a proper material flow is ensured.
It is also possible to create external processes in the module. Production orders can be monitored continuously by defining external operations. The materials that will be used during the operation can be transferred from company stock to the vendor that will perform the external operation, and the External Products resulting from the operation can be taken into inventory. These features make it easy to track the parts or the product.
The integration of the Production Management module with the Capacity Management module enables the most optimal resource planning for the relevant production order. With the help of the detailed planning types, the operations can be scheduled forward, backward or from any stage and their deadlines can be recalculated accordingly. In addition, the module provides information on resources, use of resources and BOMs. Thus, all operational data included in the relevant production processes are taken into account in the Production Management module’s planning.
Similar operations can be planned and approved together with the Operation Combination method in cases where common resources of the enterprise are used for similar operations. This feature saves time and cost by maximizing the occupancy rates of the machines in the enterprise. In addition, a prediction for the production process can be generated through the real-time monitoring of the module, if desired. Important documents for the production process such as Material Consumption Report or Production Order Report can be generated via this module.
After an operation is partially or fully completed, an amount of confirmation same as the completed amount should be given. Through the integration with the Quality Management module, the quality control process can be initiated before, during, or after the confirmation according to(in accordance with) the assigned test plan. Production Confirmation screens can be customized for any user. There are three different confirmation methods in the module: ‘Normal’, ‘Simple’ and ‘Quick’ Production Confirmation. They are named according to (in line with) the details required during confirmation.
Automatic inventory consumption of the components used during production can be made through different methods. If all operations related to the material to be produced again are confirmed, automatic inventory receipt can be performed for the product. In addition, confirmations and inventory movements can also be recorded with bar-codes or manual entries. Thus, all the components produced can be monitored completely.
ANALYSIS AND EVALUATIONS
In this module, various analyzes (analyses) to determine and evaluate the optimization potentials in production are presented to the user. These analyzes (analyses) allow the user to evaluate different topics, such as work centers or cost centers based on various criteria. It is also possible to make ‘Planned’ and ‘Actualized’ comparisons for production levels, input quantities and production quantities in this module.
In the Production Management module, semi-product WIP (Work-in-Process) analysis is also provided to calculate the value of the components currently in production. In addition, re-processing and scrap analysis are also available in the module. Thus, the production BOMs and routes, that differ from their main BOMs and routes, can be compared with their originals. The tool management feature in the module provides a source simulation to identify the resources used during the operation, as well as to determine the optimization potentials.
Through its integrated structure with the ERP system, the Production Management module can exchange information between other modules flawlessly. The module, which is fed data (whose data is fed) directly by the automation module, is also used as a data source for the Production Intelligence module.
This module has integration with modules such as Base Data Management, BOM Management, Route Management, Material Requirements Planning, Capacity Management, Sales Management, Project Management, Inventory Management, Warehouse Management, Transfer Management, Maintenance Management, Quality Management, Standard Cost Management, Production Cost Management and Cost Centers Accounting
- Alternative Management
- Variant management
- Optimization of production processes
- Usage with different production order types
- Multi-level production
- Operations Scheduling
- External Operation Management
- Operation grouping concept for similar operations
- Instant stock tracking for materials to be used in production
- Resource management
- Inventory movements that can be managed according to (based on) needs
- Diversity in operation approvals
- Effective cost management
- Detailed analysis and reporting
This module can be operated with different criterias depending on production order type and work center. Multiple planning results can be stored on the module and these results can be compared with previous plans. The performance of different strategies used in capacity planning can be compared through this feature.
There are multiple Scheduling Algorithms options supported by the Capacity Management module. Scheduling can be done by developing the most suitable algorithm for the needs of the enterprises. The extent to which scheduling, and optimization will be detailed is entirely left at the user’s initiative. Different types of planning methods can be developed for different plants in the enterprise.
VISUALIZATION AND TRANSPARENCY
The Gantt chart in the module lists the capacity utilization of each work center based on the production order or work center and graphically displays the relationship between them. With the drag-and-drop function, information such as the start time, duration and work center of operations can be managed directly. The graphical representation of Critical Path, Late Operations, Missing Parts, and General Scheduling performance in the module allows users to recognize possible errors early. In this way, rapid responses can be given to sudden developments in the chart and early intervention can be made.
TIMES AND ACTIVITIES
Production ranges can be displayed in the Capacity Management module. In this way, the period between the beginning of production and the end of the finishing process can be observed. Thanks to this data, different information such as production time, setup time and transportation time can be reached regarding the operation activities. Information on the rate of use of work centers, the rate of efficiency and operating times (start and end time, waiting time, setup time) are available in the system and can be used for production control.
COMPREHENSIVE AND NEED-BASED INFORMATION
Confirmation information for each operation is transferred live to the Capacity Management module. Here, information about production orders, such as start and end times, waiting times, workflow times, and shipping times between work centers, as well as delays in operation can be displayed. Capacity planning can be done by taking into account either the schedule of the work center or the factory calendar. The calculation is based on detailed information on waiting times, exception days, or shift system. In addition, information about the production relations and scheduling rules can be accessed through the system. Thus, production orders can be monitored, activities can be compared, and different charts can be analyzed.
ANALYSIS AND ACTION
Another function of the module is the work center comparison analysis. All the work centers involved in a particular production process can be compared and optimized. For this analysis, the user is provided with a database of detailed information on each production order step. Various benchmarks can be used to compare relevant work centers, such as setup time, actual time spent working, and machine capacity. It is also possible to display the capacity utilization in the module. This feature tells the user what resources are used and how much of the resources are used and consumed in the relevant production order. The Capacity Management module also provides data on staffing capacity, which employee to operate in which activity, staff capacity status, and other planning for non-evaluated capacities.
CUSTOMIZED SCHEDULING ALGORITHMS
Enterprise-specific capacity rules and constraints can be defined in detail to obtain maximum performance from the Capacity Management module; In addition to performing an analysis of possible delays, it is also possible to optimize the setup times and organize the resources. On the other hand, priority rules can be defined on a plant (organization) basis and performances can be compared there as well. Sequence-dependent setup times (including inter-operation times) can be determined and specific constraints can be defined for preparation times. Another function of the module is to create capacity groups. Work centers with the same or similar tasks in terms of capacity can be grouped. Capacity bottlenecks also play an important role in this module.
The integration of the Capacity Management module with the entire system provides considerable advantages in production scheduling. Managing all processes through a single system allows users to evaluate and analyze the overall situation of companies by greatly reducing the workload and risks. According to (in line with) the results of production planning evaluated after the scheduling, the actions to be taken are much faster and more convenient thanks to full integration. The module is closely integrated with Production Management, Material Requirements Planning, Maintenance Management and Routing Management modules.
- Scheduling algorithms that can be improved according to (based on) needs of enterprise
- Compare capacity plans on Gantt Chart
- Compare performance
- Operation management with drag-and-drop function
- Optimization of production times and resources
- Setup optimization
- Analysis and report
In addition to preventing system outages and prolonging machine up time, efficient operation of maintenance work ensures a secure workflow. Companies can guarantee their work security with this module.
Performing periodic maintenance works to maintain the functional integrity of the companies’ technical systems requires a careful follow-up process. The devices and systems used for maintenance are defined as maintenance objects and their updated records are kept in the module. Thus, maintenance methods can be determined for each maintenance object and the necessary definitions can be made with the Routing Management module. Additionally, the machine type and periodic maintenance interval data are stored in the Base Data Management module and the serial number is saved in the Maintenance Management module. With these records, maintenance plans are created according to the data defined in the system for each serial number. The planning process for maintenance can be done by the user as well as set to be automatically done in regular periods. The planning process takes place automatically according to the type and period of the periodic control to be made, and the planned time is then saved as a maintenance plan. The Maintenance Management module allows companies to easily monitor maintenance plans.
REPAIRS DURING FAILURE
Failure to respond to unexpected situations, such as system failures, fast and systematically can cause financial losses to companies due to activation of replacement systems and overtime. For this reason, in such non-periodical maintenance, companies need to take quick action. In the repairs performed after a failure, the Maintenance Management module records failure messages and works done to repair the technical problem in the system. Thus, a maintenance order is created based on the general information registered on the maintenance to be performed. This fast-moving process provides companies with information on the time and spare parts needed.
Once a maintenance order has been executed, a confirmation for the applied procedure is given. In this way, details such as periodic maintenance or repair of which maintenance object is applied and how much time it is performed and if any spare parts are used are recorded in the system.
PROCUREMENT OF SPARE PARTS
When a maintenance order is initiated for periodic maintenance or a failure, the system can be used to identify and plan materials such as spare parts required to fulfill this order. With its successful integration with other modules, the Maintenance Management module offers companies fast solutions. All spare parts that can be considered for a maintenance object are saved in the Bill of Materials Management module. The used components are taken out of stock automatically or manually according to the user’s preference through the Inventory Management module during approval. With the Material Requirements Planning module, the procurement processes of the missing parts required for a maintenance or repair work can be created automatically. This procurement process is carried out by the Purchase Management module or Production Management module. When the purchased parts are delivered, they are saved in the Inventory Management module as the available stock with the goods receipt and used for the necessary maintenance. With the ERP system, companies can easily perform complex processes such as maintenance, spare part procurement and stock management.
EVALUATION AND ANALYSIS
All available information collected for maintenance purposes may be used as the basis for more systematic generation and execution of future maintenance plans. With a variety of assessments made through the Maintenance Management module, companies have the opportunity to make maintenance of their technical systems in a foreseeable way and to secure their workflows in a timely manner. Various analyses can be performed with confirmations from maintenance and repair orders and base data from periodic checklists. These analyzes contain information on complaints and maintenance work that occurred during the period after the end of the maintenance period. Such assessments provide companies with reports on reasons, solutions and time spent on maintenance work. In addition, the integration of the module with the Production Cost Management module allows the final costs of maintenance and repair work to be performed and control of costs.
Users do not need any interface to link modules between the ERP software, which works flawlessly with all modules. Thus, the data is kept up to date and the processes required for the maintenance service are started automatically. The information stored in the Bill of Materials Management, Routing Management, and Base Data Management modules create a base of data for the creation of maintenance plans. Maintenance plans and maintenance orders are created and executed through the Material Requirements Planning and Maintenance Management modules. The procurement process of the required spare parts is also carried out with the help of the Materials Requirements Planning, Inventory Management, Purchase Management and Production Management modules. It is vital that preventive maintenance work is carried out in order to use the technical systems for a long time with high performance. For this reason, information on the necessary maintenance plans is obtained early from all relevant modules, measures are implemented effectively, and efficiency is ensured.
• Maintenance component arrangement (Machines and systems)
• Creating periodic maintenance plans
• System recommendations for upcoming maintenance plans
• Creating and processing periodic maintenance orders
• Inspection of maintenance and repair work according to capacities
• Failure Management
• Chronological maintenance lists
• Checklists for information on the status of maintenance plans
• Calculation of maintenance costs
• Various analyses for maintenance orders and maintenance approvals
• Complete integration into the overall system
The efficiency of the production environment can be monitored in real time with the KPIs (Key Performance Indicators) that can be defined for a Plant, Production Line, Capacity Groups and Work Centers. Through the extremely flexible structure of KPI definitions, deviations can be followed based on the period defined for production environments in the system.
OVERALL EQUIPMENT EFFECTIVENESS – OEE
Total Equipment Efficiency (OEE), one of the tools used in lean production applications, focuses on increasing the performance of machinery and equipment within enterprises. Based on three main factors—Availability, Performance, and Quality, OEE focuses on losses such as downtime, failures, scraps, and rework.
Availability score is calculated by taking the ratio of time spent on production to the planned time for production. The performance score is calculated by taking the ratio of the actual speed to the planned speed on the production order. Finally, Overall Equipment Effectiveness is calculated by multiplying these three scores.
The OEE report can be examined on tables and histograms, as well as by grouping based on daily, weekly, monthly, yearly periods and material, capacity group, work center, shift and personnel.
LIVE PRODUCTION MONITORING
With the Live Production Monitoring feature found in the Production Intelligence module, it is possible to track the production processes in the work centers based on periods via user-defined key performance indicators. Detailed information such as instant operation information, live speed graph, planned – realized activity times, quality products, scraps and rework amount of each work center can be accessed with this feature.
By using the Production Intelligence module, planned and actual activity times based on production order operation and scraps, rework, by-product and product quantities can be compared between two determined dates. If there is a confirmation metric for the material to be generated as a result of the operation, it is possible to report that data as well. The reporting process can be on a table or histogram.
The Production Intelligence module works in sync with the Production Management and Automation modules. The production environment data collected by the Automation module is interpreted in the Production Intelligence module and made meaningful so that the control of the production lines is ensured.
• Desired grouping in desired periods
• OEE, Availability, Performance and Quality Scores
• Actualized and planned production quantities and times
• Actualized and planned activity duration
• Times and frequency of failures according to failure codes
• Quantity and frequency of scraps according to scrap codes
• Quantity and frequency of rework according to rework codes.
• Additional information (temperature, pressure, etc.) reports
• By-product production quantities
• Production quantities, production and downtime on personnel basis.
This module works in full sync with other modules, especially the Production Management module, to process all important data related to the production stages and control the production lines.
Production systems are connected directly or via a Gateway to the ERP system so that an integrated operation is provided. In this way, work centers become an extension of the system. There is no need for extra effort to transfer work details to work centers and to collect production data from work centers. When work centers are connected to the system, the work details can be accessed directly. In the same way, any production data in the work center is reflected in the ERP system online and no delays occur.
INTERNET OF THINGS – IoT GATEWAY
Automation systems vary according to the technological infrastructure and devices used. Examples include control systems with PLC (Programmable Logic Controller), DCS (Distributed Control Systems) and HMI (Human Machine Interface) combinations, and Computer Controlled CNC machines. One of the biggest challenges in these automation systems is that there are different communication protocols resulting from the diversity of the technological infrastructures used in the system. Machines and production lines can vary considerably, depending on the industry. The data generated from these systems must be transmitted with different protocols. Therefore, the development of a common communicator is the most important point in ensuring the ability of advanced communication.
IoT Gateway in the automation module is a protocol-independent communication technology developed for automation systems. IoT Gateway is a tool that provides double-sided connectivity between ERP servers and control devices, sensors and smart devices. It allows seamless transmission of real-time industrial data directly to ERP servers. Thanks to this service, the data collected from machines managed with different types of control systems such as production, material, resource consumption (electricity, natural gas, etc.) and ambient values (temperature, pressure, etc.) can be monitored, analyzed and visualized in real time.
Data communication between different protocols and ERP can be provided with IoT Gateway technology in the automation module. Since OPC, MTConnect and some PLC models are supported by special protocols, almost all brand and model PLC, DCS, HMI combinations and Computer Controlled CNC Machines can be used to control the data flow. Thanks to the rules defined in your ERP environment specific to your business, IoT Gateway, which can interpret the data transferred between machines, can provide specific controls on these machines.
PRODUCTION COCKPIT AND LIVE PRODUCTION MONITOR
The production environment data collected with the automation module is made meaningful by interpreting it in the Production Intelligence module. The efficiency of the production environment can be monitored in real time with the KPIs (Key Performance Indicators) that can be defined for the Plant, Production Line, Capacity Groups and Work Centers. KPI definitions are highly flexible and deviations can be monitored on the basis of the period defined for production environments defined in the system.
REPORTING OF PRODUCED PRODUCTION DATA WITH PRODUCTION INTELLIGENCE
• Flexible grouping in the desired period
• OEE, Usability, Performance and Quality Scores
• Actual and planned production quantities and durations
• Actual and planned activity duration
• Stop times and frequency according to stop codes
• Waste quantities and frequency according to waste codes
• Reprocessing quantities and frequency according to reprocessing codes
• Planned/Actual report on additional information (temperature, pressure, etc.)
• By-product production quantities
• Personnel production quantities, production and downtime
Designed to manage production processes in companies, the Automation module works in sync with many modules, including the Production Management module, to process all important data related to production stages and control the production lines. Production environment data, which are seamlessly transferred to ERP servers via IoT Gateway, can be monitored and interpreted by Key Performance Indicators (KPIs) defined in the Production Intelligence module for Plant, Production line, Capacity Groups and Work Centers.
- With IoT (Internet of Things) Gateway technology, the protocol can be controlled independently between production systems with ERP synchronization
Real-time production and monitoring of environmental values
- Transferring production data via Electronic Data Interchange module
- Customizable flexible architecture