This covers both made-to-order and made-to-stock models. Every project is defined as a cost center against which all purchases and sales are managed apart from R&D and general purpose cost centers. BoMs are versioned to accommodate material changes in line with varying designs with clear tracking. Work orders are comprehensive with list of processes and FG, SG items simplifying the application. WO execution regulates each and every process in a pre-defined manner with material conversion and scrap.
Rejected components are returned to stores for replacements. Separate material requests and issues are done for consumables and non-BoM items. Scrap trend analysis is done. Shelf life tracking with respect to the bill lf lading to avail duty concessions for imports meant for exports.
The bill of material (BoM) here includes standard scraps with a provision to analyze the variance in every work order. The BoM is also process specific for example a robot hand is used to print on the containers where inks and plates are included. Quality improvisation management through AQL standard of quality control. Week wise WO/Route card planning, Batch number provision for traceability, two stage inspection methods, packing advice and multiple UOM conversions are other key requirements of the industry.
A multi-division multi-location water heater manufacturer one is Solar and the other being electric. The solar division operates on a made-to-order direct sale model and the solution comprises of enquiry till service support. On receiving an enquiry site visit is made and consultancy provided. A preparatory plan is designed against which an estimation is made and quotation given.
The electric division makes products based on forecasts as per last year sales and current market & weather trends . Sold thru’ two tier distributor network with secondary sale information captured.
Multiple shop floors wherein manufacturing of key SF goods (mainly tanks) are made after consumption of materials as per BoM. In another floor assembling of final product is done is manufactured after consuming the SFGs along with bought out items. These items include stickers, packing materials, user manuals, bulbs, electrical items pipes, etc
Service is based on warranty wherein bulk spares are transferred to employee stores. Since customers and the service engineers are distributed across south and western india, spares are transferred based on PIF (products in field) population and failure rates before hand itself. Defective spares automatically added to the engineer stores from where if it is returned and stocks verified. Non warranty replacements are tracked separately and customer bills raised.
Made-to-stock model dealing in solar & led divisions. Multi point purchase approvals by division head and technical head, value based approvals, purchase in batches, FIFO based consumption, batchwise cost management, cost variation management, weekly daily production planning, plan vs actuals analyses are some of our key offerings to this industry.
Manufacturer and exporter of high quality synthetic mosquito nets. The raw material in the form of granules undergo three processes namely knitting, weaving & stitching. Each process is done at different locations with a mix and match of own production and sub-contracting and the system is flexible enough to accommodate any possible process flow. The solution covers end-to-end automation right from raw material extrusion till packing, bale conversion and shipment. Job order rejections is connected to debit notes for easy management of job orders. Wastage is monitored and controlled process wise and also with respect to shift, cumulative and daily %. Beam weights are directly captured from weighing machines. CT-3 purchase and its tracking forms an indispensable part of the solution as it is a 100% EOU.