Advanced Manufacturing

Production Planning is a modeling process that reveals why you need to produce based on forecasting and replenishment formulas, as well as what to produce and when to produce it. MRP establishes the plan of action, including schedule formulas based on linked orders, resources, and timelines.

Production Planning

• Analyze production plans using demand & replenishment formulas.
• Minimum build qty based on firm orders vs Maximum buildable qty based on BOM inventory.
• Increase or decrease work-order demand batch-size from order ship-date projections.
• Forecast future demand based on extrapolations from past and present demand vs inventory levels.
• Incorporate surplus stock above demand based on min/max/re-order point formulas.

Material Resource Planning (MRP)

• Create production batches based on groups of finished goods, to drive work-orders.
• Review resource capacity by skill-set to meet production schedules within each work-order.
• Establish task-list templates that can later be tuned at the work-order level.
• Each work order can have tiered build-by dates driven by linked sales order ship-by dates. If one of these is compromised due to insufficient availability in a BOM hierarchy, the item is flagged and available solutions are provided.

Work-Order Management

Work-Orders are the command and control center where everything is orchestrated for manufacturing Finished-Goods.

Core Work-Order Capabilities

• Build to Stock & Build to (Sales) Order within the same Work-Order – With separate fulfillment and inventory workflow for each.
• Designated Build-Manager - Assigned to manage WIP Tasks (aka “Routing List”), Resource allocation, etc..
• Scheduling - Planned vs Start, Task schedule, etc...
• Work-Order Insights - Build, Remaining, Picked, Partial Builds, Build-progress from linked orders, Total Progress, Pickable, Buildable, etc..
• WIP Task Templates (aka “Routing List”) – Default list can be modified to fit specific needs of the work-order.
• Link to multiple contributing Sales Orders.

Work In Progress (WIP) Task Management (aka “Routing”)

• Uses CRM Activity Management to alert task assignees, with links back to their task.
• Resource scheduling with labor-hours estimate. View skill-grade, and capacity load by resources / teams.
• Attach documents for each task.
• Pre-build task prep includes change of workstations, hours, minutes, etc...

Bill of Materials (BOM)

• Partial and full pick to build (Partial builds can be shipped out or put-away on-demand).
• Ability to unclog bottlenecks that stall production with BOM substitutions and child work-orders (See the BOM section for more detail).

Finished Goods (Master-Assemblies) sit at the top of the hierarchical layers that make up the bill of materials (BOMs). Any item in the hierarchy can also be sold individually with its own unit of measure (UOM). That demand is managed within Production planning and MRP to strike the right balance between resource availability and demand.

Bill of Materials (BOM)

Master-Assembly Control

Dynamic BOM substitutions reduce production delays

• Comprehensive Parts & Materials substitution - Back-ordered items holding back a build can can quickly be substituted with equivalents from within the warehouse, transferred from nearest warehouse.
• Insufficient Sub-Assembly Qty replenishment - Create child work-orders for buildable sub-assemblies to satisfy quantities needed to complete parent work-orders, each with it’s own compliment of BOM substitution controls.
• Procure Materials from the BOM - If all substitution and build replenishment options have been exhausted, you’ll be able to create POs from the materials in question right from the work-order, with all items benefiting from hard-allocation to circumvent the possibility of being picked by open sales-orders.
• Hard-allocated POs & Transfer-Orders for back-ordered BOMs - Assures that inbound vendor shipments make it directly to the workstation awaiting materials on the shop-floor so production can continue.

Product Configurator

• Configure to Stock, Quote and/or Order (including configurable task-lists).
• All items types are supported (Including parts, materials, services, and non-inventory).
• Dynamic Price Roll-up - Base the final configured prices on a roll-up of items selected, which can include list, cost, and other price calculations.
• Skip & inclusion logic and automated downstream selections make complex combinations easy for anyone to configure.
• Extendable to BizCommerce so your customers can custom configure from your website to create sales-orders within BizAutomation.

Just-In-Time (JIT) Kitting

JIT Kitting can be setup to bypass more complex work-order processes, and can be run completely within sales orders, which can make sense when BOMs are limited to 3 levels and where “light” assembly workflow is desired.

• JIT Kits leverage the product configurator.
• Runs completely within the sales-order framework  (including configurable task-lists).
• Hard allocation workflow ensures that kit items from both inbound back-order shipments and stock items, are protected from orders competing for the same items, to prevent stock-outs and shipment delays.