ERP-Production Module

Presented To: Ms. Sudha Singh

Presented By:
Amalesh Deka
Ankita Gupta
Anoop Singh
Anshita
Arpita Panda
AP-VII, NIFT-Bengaluru

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
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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

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Case Study of Production

Module

SAP
Visual GEMS
APPS
PROMAN 3.0

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Production planning
module

SAP Modules
SD Sales and
Distribution
SD
MM Materials
Management
MM
PP Production
Planning
PP

QM

FI Financial
Accounting
CO Controlling

FI
CO

AM

SAP R/3

QM Quality
PM
Management
PM Plant
WM
Maintenance
WM Warehouse
Management

HR
WF

PS

AM Asset
Management

HR Human Resources
WF Workflow

PS Project System

Production Planning Module

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

SAP-Production Planning
Customers

SD
Sales
Shipping
Billing

Vendors

FI

Financial
accounting

Purchasing MM
SD
Warehouse
Invoice
verification

CO

Cost
accounting

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

PS
SD
Project
Networks
PM
SD
Maintenance
Repairs
Plant
maintenance
QM
SD
Inbound Raw
Material
Finished Goods

Human
resources

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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PRODUCTION
MANAGEMENT MODULE

START

IE GIVES THE PRODUCTION

PLAN
Production Manager reviews the
Production Plan

Production Department receives

materials from the Inventory
Patterns from Pattern
Making Department

INVENTORY
DEPARTMENT

SPREADING

CUTTING

CONTINUED

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CONTINUED

Cut Pieces instantly moved

to Sewing Line

NO
Kept for Inventory WIP

YES
Cut Pieces Transported to Assembly Line

Line Balancing

Assembly Line

Inspection
CONTINUED

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CONTINUED

Matches with
Fixed
Standard?

NO

Defect can be
modified?

NO

Reject the
Piece

YES

YES

MODIFICATION
Final output sent to Finishing
Department

END

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Click on the above Module Names to see screen forms)

Export Orders
Export Order Entry
Style Data Bank/Dispatch
Fabric Working
Yarn Working
Sample Approval
Measurement Charts
Costing Template
EO Closure / Locking

Inventory

Purchase Order For

# Fabric
# Accessory
# Yarn
# Garment

Order Closure

Production Planning
Production Orders
Processing Orders

Accessory Stock
Fabric Stock
Yarn Stock
Garments Stock
Opening Stock
Gate Pass
Issue Control Centre

Purchase Orders

Production

Import

Production Monitoring
Production Reconciliation
Import Monitoring Data
Order Closure

Export Documentation

Import L/C
Import Bill entry

Export LC
Quota
Export Incentives (DBK)

Import L/C Register

Back To Back L/C
PO Without L/C Import Bill tracking

Pre-shipment Invoice Packing List

Commercial Invoice
Draft / Bill of exchange
Bank certificate

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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 whichmonitors all activities on
the shop floorfrom 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
usefulMIS reports to remove bottlenecks and improve productivity.
This can also seamlessly integrate with STAGE or work independently.
PROMANimproves profitability, reduces production costs, improves
product quality.

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PROMAN 3.0

PROAMNidentifies bottlenecksin 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 Progressat each location can be generated

Option to plan capacities withlearning 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 usingbundles

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!!!
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