Manufacturing Management System

Production

FALCON ERP MFG manufacturing/ production management offers easy-to-use production management capabilities that support production planning, dispatching, production status monitoring, managing bills of material, shipping control, reporting of production activity and many more activities. FALCON ERP production management is designed for specific needs of manufacture industries that help organizations to get the production on time, and on budget.

• FALCON ERP production management improves efficiency of manufacturing operations
• Provides real-time visibility and management control
• Streamline production life cycle
• Keep up-to-date information on the components and sub-contractors used to produce your product, better balance lead times, reduce inventories, and improve cash flow.
• Manage all aspects of receiving materials, returning goods, shipping finished goods.

Bill of Materials:

At the heart of product definition for produced items in the FALCON ERP MFG system are bills of material (BOM’s). BOM’s are primarily used for discrete manufacturing, assembly, and kitting processes in FALCON ERP MFG. BOM’s can have infinite levels and include pseudos, subassemblies, and phantoms. Through the engineering change processes in FALCON ERP MFG, BOM’s can go through version revisions. FALCON ERP MFG includes where-used functionality for visibility to where specific components and subassemblies are used across all products, enabling rapid mass change processing.

Bill of Materials Highlights

• Supports infinite-level bills of material (BOM)
• System maintained version and revision control with a fully-integrated engineering change order process
• BOM’s support pseudos, subassemblies, and phantoms and can have an infinite number of lines of notes
• Supports online review of BOM’s via single-level and multi-level explosion
• Multi-level where-used functionality enables rapid access and mass change to all BOM’s using a specific component material or subassembly.
• BOM’s are easily duplicated and updated for the same product or a new product
• BOM’s are pulled into work orders for tracking and recording of actual components and subassemblies consumed or backflushed at standard
• BOM’s support yielding at the top level or component level and rank-ordered component substitutes

Routing Maintenance:

Routings consist of a series of steps which define the sequenced processes and work centers a given product must go through for its production.

FALCON ERP MFG material requirements planning (MRP) and production scheduling processes generate work orders and batch runs based on a product’s routings. Individual routing steps define anticipated process standards, and can either be established as the amount of time to produce a given quantity of product, or as the quantity of product which can be produced per unit of time. Routings also include defined standard setup and queue times by process step.

In FALCON ERP MFG , a product can have an infinite number of active routings defined at either the organization or facility level, with a specified rank ordering of routings. In the MRP process, FALCON ERP MFG uses product routines and other associated data to systemically create tentative production schedules by facility to best meet anticipated customer demand.

Routing Maintenance Highlights

• Routings support revision levels, version tracking, and affectivity dates
• Supports routing run time by operation step entered as either units per time or time per unit
• Supports standard setup and queue times by routing operation step
• Support by-products and co-products
• Supports the entry of raw materials, components, or ingredients consumed per routing step or operation
• Supports unlimited work instructions and notes by routing and individual step
• Supports subcontracted and outside third-party processing within routings
• Supports entry of labor required per routing step

Machine Maintenance:

FALCON ERP MFG machine maintenance software functionality provides the ability to track machine maintenance intervals and be notified when a given machine requires maintenance. Maintenance management allows for the establishment of machine component lists and associated mean-time between failure standards, creation of standardized procedure lists, and the association of procedures and maintenance documents to specific machines and processes. FALCON ERP MFG production scheduling and maintenance management functionality are fully integrated, thus allowing for time to be reserved on the production schedule for preventative maintenance activities. In addition, plant floor personnel can immediately initiate machine maintenance in the event of machine anomalies and downtime.

Machine Maintenance Highlights

• Supports preventive or scheduled maintenance and non-planned or on-demand maintenance request
• Downtime resulting from scheduled equipment maintenance activities is included in production scheduling activities
• System notifications of preventive maintenance orders which require machine downtime
• Supports entry of a machine BOM or equipment part list and on-line maintenance instructions
• Supports creation of maintenance work orders and scheduling of associated maintenance labor requirements
• Plans purchases of items, which are managed in inventory and consumed by maintenance activities

Material Requirements Planning (MRP) Highlights

• Performs time-phased requirements planning for single and multi-facility manufacturing organizations
• Generates online purchase requisitions and tentative production schedules
• Uses customer demand in the form of sales orders and forecasts
• Uses inventory levels and associated replenishment methodologies
• Uses multi-level bills of material, routings, and available production capacity
• Uses supplier information such as lead times and purchase order requirements
• Calculates expected inventory levels over time and generates purchase requisitions with appropriate time offsets to meet future projected inventory shortfall

Production Scheduling

In FALCON ERP MFG , production schedules, consisting of a series of work orders, can be created manually and generated. To generate the tentative production schedule, organizations establish a master production calendar which defines hours of operation by day and shift and the associated labor pool that will be available during those times.

Through the MRP process, tentative production scheduling is capacity-constrained, and is generated based on material, machine, and labor availability. The tentative production schedule can be reviewed by manufacturing planners and changed as desired. The tentative production schedule’s suggested work orders can be rescheduled and resequenced. The tentative production schedule can then be converted in part or in whole to the final production schedule. Both the tentative and final production schedules can be viewed tabular format by machine, process, or entire facility.

Production Scheduling Highlights

• Production schedules can be created
• Tentative production schedules are generated based on a master production calendar
• Master production calendar defines hours of operation by day and shift and associated available labor pool
• Tentative production scheduling is capacity-constrained, and is generated based on material, machine, and labor availability
• Tentative production schedule can be reviewed and changed as desired
• Work orders can be rescheduled and resequenced
• Tentative production schedule is converted in part or in whole to the final production schedule
• Both the tentative and final production schedules can be viewed tabular format by machine, process, or facility
• Final production schedule updates with color-coded alerts, highlighting issues that may occur based on delayed and out-of-spec production process rates
• Final production schedule’s work orders feed shop floor production reporting

Work in Progress

To track the activity of the manufacturing process and manage the performance of the shop floor in order to minimize job costs, efficiently utilize production resources and provide comparative reporting.

The Value of Work in Progress

• Support mixed-mode manufacturing environments
• Track and manage material and operational costs per job
• Monitor job variances comparing actual to standard
• Analyze efficiency and utilization of shop floor elements
• Track production overheads, resources, and scrap
• Schedule jobs according to the production calendar
• Identify overloaded work centers
• Create jobs from Sales Orders and MRP
• Link purchase orders to jobs to expedite receiving
• Automatically manage the production of co- and by-products

Matching Work in Progress to your business

• Define productive unit and work center capacity
• Determine standards for machines and employees
• Optionally include non-productive time in job costs
• Create jobs for standard or custom product
• Issue materials and labor to jobs in kits or by item
• Post labor at standard or actual employee rate
• Integrate with bar code data collection systems
• Record costs incurred on subcontracted operations
• Receive completed items into inspection or directly into inventory
• Easily create rework jobs
• Multi-level job query facility
• Reserve and track lot and serialized item
• Recalculate expected costs Integration