Production Management

PRODUCTION MANAGEMENT

Whether you manufacture complex solutions or simple products, you need strong production control in order to build a competitive advantage. As the global marketplace continues to shrink profit margins and customers become more demanding, businesses are looking for agile solutions that can provide the infrastructure they need to respond quickly and efficiently. Epicor offers a comprehensive solution for make-to-order, mixed-mode, make-to-stock, engineer-to-order, and configure–to-order manufacturers; including light assembly features for distribution businesses. Modular in design, the production control suite of modules include Job Management, Lean Manufacturing, Manufacturing Execution System (MES), Quality Assurance, and Advanced Quality Management.

Features

Job Management

Job Management is a comprehensive production control solution designed specifically for the planning, routing, scheduling, costing, and tracking of products; including assembled, manufactured, and semi-finished products. It includes innovative tools for better planning and costing with historical run analysis that compares estimates to actuals on a run-by-run basis. With Epicor Job Management, users can more easily identify wasted processes and continuous improvement opportunities on the production floor for maximized profitability.

Access all job related actions in a single view—the creation of new jobs, changing job requirements to match changing demand, and allocating and reallocating jobs to satisfy changing customer demand. The planning workbench allows seamless access to the scheduling board for more detailed job management.

Quickly review the relationship between production jobs and demand. Make changes to the production plan to accommodate new and changing demand.

The Production Planners Workbench is a dashboard that provides an overview of the material shortages of the selected jobs. Although this information is already available in each job this overview gives the job planner a tool to quickly gather information for multiple jobs at once.

Compare actual to estimates online, review job costing for materials, material burden, subcontracting, operations (labor/burden), and compare projected and actual billings for profitability analysis. Job costing can be performed on a job-by-job, customer, part product group, or overall company basis.

Handle one job or one delivery, one job or multiple deliveries, blanket production runs, and internal work orders to build parts to finished goods inventory.

Verify that orders or changes don’t fall through the cracks for viewing and selecting new orders and change orders from job entry. Optionally track all job changes via user ID, date and description.

Simplify the planning process. Use a tree interface to easily drag-and-drop components, operations or direct materials from another quote, BOM or previously run job.

Produce and auto-receive overproduction quantities to inventory.

Everyone has it. Yield Scrap. This functionality offers the ability for scrap reporting at an operation to affect the estimated production quantity of subsequent operations if the scrap exceeds a predetermined scrap allowance. Some users may just want a warning others may want automated predefined actions.

Produce routings, costing, and tracking of single or multiple-level parts.

Schedule jobs based on forward, backward, what-if, finite, and infinite capacity.

Backflush labor and/or materials for a single assembly, branch, or an entire job.

Review a specific job, and check the status of all assemblies, operations and materials, including subcontract status.

Track and analyze efficiency and utilization figures by employee, operation, work center, and department.

Extensively track and analyze scrap, rework and added operations.

Query material availability at the time of job entry to determine whether jobs can be started within the scheduled time period.

Advanced Production

Advanced Production deploys batching technology that enables users to group multiple parts or operations together for key production processes. The result of this batching process is a single reporting entity or job for simplified scheduling, tracking, and reporting of labor and materials on the plant floor.

The functionality of Advanced Production is available in the job planning and resource scheduling functions within Epicor. Both planned and “on-the-fly“ grouping provides powerful flexibility to end users. Additionally, users can select to plan sequentially one operation after another or concurrently—operations to be complete at the same time for nested operations.

Offers simplified production of co or dependent products in the same production run.

Offers simplified production of nested or products of the same material or process in the same production run.

Easily link multiple operations from the same part of different parts to be run either sequentially or concurrently.

Single source production enables full visibility and tracking of source operations and parts.

Material and production costs are applied accurately to multiple jobs as production is complete. Simplified labor entry allows plant floor employees to enter quantities for multiple parts in a single step.

Single reporting entity enables multiple part quantities to be entered in a single plant floor interface while accurate labor and burden cost is accurately applied to each batched part and operation.

Flexible to handle multiple production requirements, user can select to either link parts and operations concurrently—to be run one after another or concurrently—at the same time.

Flexible to handle multiple production requirements, user can select either a single operation for linking or to link an entire job.

Lean Production

With increased global competition and the demands of an online supply-chain, customers have more influence than ever before. Customers are, demanding greater product flexibility, smaller, more frequent deliveries and higher product quality, at a lower price.

Businesses are widening the scope and focus of lean principles to encompass all processes that contribute to the bottom line. The true benefits of lean thinking will only be fully realized when the entire enterprise adopts the lean ideology.

Specific functionality has been developed in Epicor for plant floor operations that are adopting work order less Kanban manufacturing strategies in part or fully to pull rather than push products through the manufacturing process. Epicor Lean Manufacturing Kanban functionality supports this.

Epicor embedded Kanban functionality (i.e., a signal to manufacture or move product) offers the functionality required to manage several types of systems for Kanban control. As inventory levels or order demand require additional product, Kanbans, such as manufacturing real-time Kanbans, manufacturing flow Kanbans, purchase real-time Kanbans, and stock replenishment Kanbans, are automatically requested. The Kanban manages the stocking and order demand for parts flagged as needing Kanban control. Userdefined rules enable parts to be flagged for Kanban control at the part, warehouse, or individual bin or cell location level.

Manage, plan, and replenish materials within a cell.

Eliminate work orders and reduce on-hand inventories as parts are electronically triggered for replenishment as needed with real-time manufacturing Kanbans. Instead of planning for each order that is processed, parts are pulled through production as inventory or cell stocking levels fall below minimums. The cell is visually queued to produce based on the Kanban quantity for the part at its warehouse, bin or cell location.

View future demand to dynamically calculate future replenishment Kanbans with the manufacturing flow Kanban. This gives downstream cells and suppliers visibility of future demand (although the actual Kanban events may differ during execution). As Kanbans are acted on, the downstream demand requirement is dynamically updated. All cells and suppliers have up-to-date visibility of future demand.

Move inventory as it is needed in a particular manufacturing cell, shipping area or customer consignment location with the real-time stock replenishment Kanban using automatic triggering of stocked inventory.

Use the real-time purchase Kanban to replenish directly from the supplier and notify purchasing that a stock replenishment is required. Automatically send an e-mail to the supplier requesting additional inventory against an open purchase contract. Inventory can be received to the main stores, or directly to the production floor. Real-time purchase Kanban automates the replenishment of material from vendors and provides for visibility of current supply requests.

Authorize supplying cells to make a predefined quantity of an item being “pulled“ by using operations.

Employ a phased approach to implementing lean practices for tracking material, MRP and Kanban in a mixed environment. By offering manufacturers the choice, at the part location level, how the part will be managed, manufacturers can more easily migrate to lean, while synchronizing MRP and Kanban execution.

Manufacturing Execution System

The Manufacturing Execution System is an easy-to-use, online system for the plant floor that allows plant-based transactions real-time visibility throughout the Epicor solution. This easy to use interface is developed for end users and offers options of deployment that include touchscreen monitors as well as bar coded enablement to simplify data entry while reducing mistakes.

Epicor MES provides accurate labor reporting, a vital concerning job costing and job status. Online transaction tracking gives management a current picture of what is occurring on the plant floor by employee and job.

Integration with Epicor Job Management, Scheduling, Quality Assurance, and Advanced Material Management eliminates dual entry and provides online, real-time views of the latest plant floor scheduling priorities. In addition, integrated document management allows plant floor access to needed documentation including product drawings, process documents—even multimedia videos of difficult to explain processes.

Use touchscreen, mouse, bar code, or keyboard interface to update labor information from the plant floor. Eliminate data entry mistakes and increase transaction speed by simply scanning a bar code tag to complete a transaction.

Incorporate employee pictures, product and process documents, including product CAD/CAM drawings or even video instructions on how to perform a process.

Provide employees with prioritized work schedules and make information directly available to the plant floor.

Display the Manufacturing Execution System screens in the employee’s primary language.

Automatically split labor hours across multiple jobs being worked on simultaneously by an employee. Likewise, split resource or machine hours when two or more employees work on the same resource.

Capture rework and scrap reason codes, along with miscellaneous employee comments from the plant floor. Use the Quality Assurance options to report setup inspection, first article, piece counts, and more.

Shop warnings appear in various locations throughout the system when certain conditions exist or certain events occur. They are intended to keep supervisors informed of a job’s status or an employee’s performance.

Manage clock-in and clock-out periods with adjustments made for user-defined grace periods. Accommodate split and staggered shifts.

Users can access online trackers on the plant floor from within MES. From Job Tracker, Order Tracker, Customer Tracker, Shipment Tracker, and more are available based on login and secure access.

Access who’s here, who’s not here, current work center activity, as well as user-defined alert conditions from the plant floor.

In combination with Advanced Material Management, maximize responsiveness in the warehouse with Shipping and Receiving functions from within MES.

In combination with Advanced Material Management, maximize responsiveness in the warehouse with Inventory functions such as adjustment, material issues, physical inventory counts from within MES.

In combination with Advanced Material Management, maximize responsiveness of material handlers with material move queues and give operators the ability to request in process WIP moves of product from one location to another, maximizing control of in process products while reducing delays. Additionally, move WIP products into inventory storage locations or stage WIP at the next resource based on available space and time. Quickly and accurately identify WIP and inventory containers with system generated bar codes.

Quality Assurance

Extending your solution with Quality Assurance ensures that complete visibility of quality operations including visibility of items in the quality process. Accurate costing demands that products moved through quality accurately reflect their value and are removed from appropriate WIP. Additionally, this module includes processes for supplier returns with links to Accounts Payable for automated debit processing; closing the loop on traceability of products in and out of quality within the plant.

Tie together all quality functions, whether it’s scrapping end parts, rejecting raw materials or tracking first article inspections. Inspectors have queues of items to inspect with full disposition and corrective action follow-up. Plant floor employees can flag parts as nonconformant, which moves them into an inspection queue. Parts that fail inspection may be flagged for review by a material review board.

Monitor WIP, review all inspections in priority and automatically take action on those requirements from the inspection workbench. Inspectors move passed parts back to jobs and failed parts into discrepant material report (DMR) processing, or they simply scrap them.

Create a nonconformant record (NCR) for all nonconformant parts. From a job, shop floor employees automatically create an NCR when they scrap an end part or raw material. Inventory personnel create an NCR when they scrap parts from inventory.

Use non-nettable bins to keep parts undergoing inspection or on-hand quantities.

After failing inspection, create a DMR to provide the MRB with an online queue of parts that need to be dis-positioned.

Create and track all preventive and corrective actions online. With due dates, audit sign-offs and unlimited comments, corrective actions provide for follow-up of quality issues.

Disposition parts by an MRB after failing inspection. Online documentation provides an audit trail of MRB actions.

Generate cost of quality reports to identify how much quality problems are costing you, whether parts are scrapped from inventory, a job or receipt inspection.

Print a customizable packing slip for all parts returned.

Create a debit memo in DMR processing and it is automatically tied to accounts payable.

View inventory transaction detail occurring in inspection and DMR processing with the material transaction detail report.

Businesses are increasingly requiring detailed compliance documentation. Depending upon the industry, this documentation is commonly referred to as Certificates of Analysis (COA), Certificates of Quality (COQ), or Certificates of Compliance. To help manage this documentation, Epicor includes the ability to check for Certificates of Compliance at receiving of materials from suppliers, receiving of in process parts from outside operation suppliers, and before shipping products to customers.

Advanced Quality Management

Epicor Advanced Quality Management (AQM) provides the foundation for significant productivity improvements and cost reductions across your entire enterprise. This solution includes Product and Process Documentation, Customer and Supplier Management, Nonconformance and Corrective Action capability. These modules provide a complete framework for compliance with regulatory and industry standards, including ISO, automotive (TS), aerospace (AS), and FDA (21CFR 11) requirements.

At the same time, you can manage financial processes for warranty issues, audit results and approval trails, which are reporting requirements for Sarbanes-Oxley and TREAD Act compliance.

Epicor AQM provides the foundation for significant productivity improvements and cost reductions across your entire enterprise. This solution includes Product and Process Documentation, Customer and Supplier Management, Nonconformance, and Corrective Action capability.

Industry and regulatory compliance requires three basic capabilities: process control, documentation and visibility. The Compliance & Audit solution, implemented in concert with Epicor AQM core capabilities, enables you to automate your business processes, share key information, provide process documentation, traceability, and track existing and potential
issues through effective resolution. Have your product documentation, employee skill sets, nonconformance and corrective action records at your fingertips to ensure compliance to ISO, automotive (TS), aerospace (AS), and FDA (21CFR 11) requirements.

Create a master list of all corporate documentation, including work instructions, policies and employee records. Assure obsolete documents are removed from circulation.

Epicor AQM Data Collection and statistical process control (SPC) enables you to gather all the key data required for receiving, in-process and final inspections. It provides automated management of inspection plans for each operation of business processes, with complete revision control and change history. Collect data against these operations and chart results for controlling these processes and achieving continuous improvement.

These integrated productivity tools strengthen the management of all preventive and reactive equipment maintenance activities. This solution maintains accurate online records of all maintenance work order and calibration activities. Manage scheduling, procedures, down time, and labor costs for historical records and traceability.

Epicor AQM product launch defines, automates and documents the critical aspects of your product launch process to assure engineering design information is translated effectively throughout the pre-production process. Advanced product quality planning (APQP) management enables you to synchronize all key processes and activities through the creation of templates, project plans and checklists that manage all details of the launch process. The solution also manages the quality of parts through a series of highly controlled submission warrants, checklists and approval routings, as required by industry-specific quality methodologies, including production part approval process (PPAP), initial sample inspection report (ISIR), and First Article. All part specifications and modifications are documented and communicated to promote error-free production runs.