Manufacturing Execution / MRP & Inventory Performance Management

1. Total Number of Slides: 11
REVL ( KML Division)
MRP & INVENTORY PERFORMANCE MANAGEMENT SYSTEM

2.  About MRP & Inventory Performance Management System
 System Interface with SAP R/3
 Design Objective
 Major Processes – IT Enabled
 Production Planning/Scheduling Process – Module Demonstration
 eMIS
 Benefits Derived
Slide No : 2
Contents

3.  Business Productivity Tool for High Variety Valve Manufacturing
Slide No : 3
Technology : Client / Server
Platform : Sybase
 IT System - Interfaced with Modules of SAP ( MM / PP / QM / SD )
About MRP & Inventory Performance Management System

4.  To Make IT Simple And Adoptable
 To Improve & Support Various Internal Processes
 To Mobilize SAP Data Across the Functions
 To Provide Instant Visibility / Inventory Performance
across the Plant
Slide No : 4
Objective

5. Slide No : 5
SN Modules Processes/Work Flow Addressed SAP
Interfaced
Respective Areas of Functions
1 Product Info Management - Product Database
- Drawing Release / Access to Operation Team
- To help rationalization of Stage Codes
Engineering
2 Sales Forecast [AOP/Orders] - SBP / AOP RM Requirements
- Integration of Customer Orders with Production Planning
Module
Marketing
3 Sales / Production Rolling
Plan
- Online Capturing of MTS/ MTO Requirements
- Production Planning based on Plant Capacity
- Daily/Weekly Plan Vs Actual Monitoring & Review
a) Cellwise
b) Segementwise
c) Customerwise
- Generation of RM Shortage List / Monitoring & Review
- Plan Amendments
Production Planning & Control
4 Inventory Ageing Analysis - Monitoring and Review of Stock Ageing ( RM, WIP, FG ) Materials / Manufacturing / Marketing
5 Inventory Analysis - Indirect Material Inventory Analysis Materials
6 Scrap Analysis - In Process Scrap Analysis and Monitoring Manufacturing
7 Rework Analysis - Rework Accounting / Monitoring & Review Manufacturing
8 Sales Analysis - Sales Analysis Marketing
9 Assets - 2D Barcoding of Assets and Verification
Finance
10 MRP DRM Performance - MRP DRM Monitoring / Review MRP
Major Process – IT Enabled…….

6. Slide No : 6
SN Modules Processes/Work Flow Addressed SAP
Interfaced
Respective Areas of Functions
1 Product Info Management - Product Database
- Drawing Release / Access to Operation Team
- To help rationalization of Stage Codes
Engineering
2 Sales Forecast [AOP/Orders] - SBP / AOP RM Requirements
- Integration of Customer Orders with Production Planning
Module
Marketing
3 Sales / Production Rolling
Plan
- Online Capturing of MTS/ MTO Requirements
- Production Planning based on Plant Capacity
- Daily/Weekly Plan Vs Actual Monitoring & Review
a) Cellwise
b) Segementwise
c) Customerwise
- Generation of RM Shortage List / Monitoring & Review
- Plan Amendments
Production Planning & Control
4 Inventory Ageing Analysis - Monitoring and Review of Stock Ageing ( RM, WIP, FG ) Materials / Manufacturing / Marketing
5 Inventory Analysis - Indirect Material Inventory Analysis Materials
6 Scrap Analysis - In Process Scrap Analysis and Monitoring Manufacturing
7 Rework Analysis - Rework Accounting / Monitoring & Review Manufacturing
8 Sales Analysis - Sales Analysis Marketing
9 Assets - 2D Barcoding of Assets and Verification
Finance
10 MRP DRM Performance - MRP DRM Monitoring / Review MRP
Major Processes - IT Enabled………..

7. Slide No : 7
Production Planning / Scheduling Process @ KML Division

8. Slide No : 8
 To Automate Production Planning Work Flow
 To Enable On-line Review of Various Operational Performance
a)Inventory Performance
b)Manufacturing Performance
c)SAP DRM Performance
 To Automate Creation and Distribution of MIS reports
( Plan Vs Actuals / Scrap / Inventory / Ageing Status to entire Operation Team )
 To Improve WIP Accounting.
 To Establish Effective Co-Ordination among Functions
( Marketing / Production / Materials )
 To Improve MRP accuracy / results
Production Planning/Scheduling Module - Purpose

9. Software Demo
Slide No : 9
Software Demo

10. Slide No : 10
Company Level
- Absolute System Driven Production Planning Process
- Improved End To End Visibility And Effective Management of Inventory
More importantly proactive prompting of systems factual data in a standard form, drives each one to act quickly / appropriately.
Plant Level
- Improved Production Target Setting Process for the Month
- Better Capacity Planning / Utilization
- Control Over WIP
- Improved Material Accounting
Marketing
- Improved CFI
- Simplified, Flow of Orders & Schedules
Shop Floor
Manager Level
- Improved Daily Review Over Plan Vs Actual Production
Cell Leader Level
- Improved PDCA for achieving Daily Average Output
- Improved Accountability Over WIP
Quality
- Quick Analysis / Control over Scrap on Daily Basis
Materials
- Improved Planning & Positioning of RM @ Plant
User Level
- User Friendly
- Menu Driven ( No need of transaction code )
- No Wait Time / Follow-up for MIS
Benefits Derived @ all levels

11. Slide No : 11
Thank You