Global PFS-management of process production

• System scope==

The software package Global-Process Manufacturing provides all necessary functions for the complete solution of problems of planning and industrial process control of continued production, carrying out the flexible and thought-over production policy at the enterprise. Use of a complex opens ample opportunities on management of production processes, flows of inventory items, work centers, to quality control and many other things. Global Process Manufacturing is Global ERP system component, and can function as independently, and in interaction with other system modules. A complex scope – any manufacturing enterprises having a need for automation of continued production, such industries as:

• metallurgical;
• chemical and petrochemical;
• polygraphic;
• pharmaceutical;
• food etc.

Purpose of a software package

The software package Global Process Manufacturing is intended for:

• production plannings of finished goods;
• planning of material flows;
• maintaining reference book of production operations, drawing up formulas (compoundings) and description of process flows;
• managements of works orders;
• managements of material flows and production supplies;
• managements of quality control;
• the cost accounting on production;
• accounting of defects and analysis of the reasons of its emergence;
• timely reflection of production operations in the accounting module;
• system management of documentation on products;
• formations of analytical and operational reports, creation of a basis for acceptance of management decisions.

Reference books

Delivery of the software package Global Process Manufacturing includes a large number of the reference books allowing to organize full accounting:

• the made products with all necessary characteristics and parameters of quality control;
• the equipment used in production processes with working schedules, data on the planned idle times, the minimum and maximum loading;
• the production personnel participating in production process with working schedules, discharges and wage rates;
• the production operations executed at the enterprise with a binding to equipment types;
• formulas (compoundings) of the made products with the list of ingredients, possible analogs and substitutes, an exit of by-products;
• the process flows, with transfer of production operations executed by production of specific products;
• work centers, as intersections of the equipment and production personnel;
• the parameters of quality checked at finished product output and incoming inspection of raw materials and materials.

Production planning

The software package Global Process Manufacturing gives following features regarding production planning:

• formation of a system of the restrictions considered when scheduling production, for example:
  • the planned sale of products;
  • available production capacities;
  • volume of available warehouse resources;
  • etc.

• planning and adjustment of the production program taking into account the actual execution of the program for previous periods;
• information display of the production plan by intervals on days, weeks, months and to quarters.
• planning of raw materials and materials for ensuring execution of the production program;
• reservation of raw materials and materials for production needs;
• possibility of the analysis of the production plan "that … if" at change of parameters of a system of restrictions and/or the principles of optimization;
• the analysis of the planned loading of work centers for preliminary determination of "narrow" places.

Works orders

On the basis of the production program the software package Global Process Manufacturing creates works orders to workshops on production of this or that type of products. Following features are provided during the work with works orders:

• control of stages of execution of the works order;
• accounting of results of execution of the works order (production);
• accounting of the inventory items spent in a production process;
• control of the key process parameters of production process;
• accounting of data on the involved production capacities and personnel;
• accounting of selection of control tests and their transfer to laboratories.

Quality control

For the organization of a quality control system at the enterprise the software package Global Process Manufacturing provides following features:

• accounting of the received control tests from each batch of inventory items;
• the magazine of transfer of control tests for testing in laboratory;
• determination of set of controlled parameters for separate positions and lots of products, raw materials and materials;
• management of the quality standards;
• determination of procedures of tests;
• registration of process and results of testing;
• grade assignment to lots of products;
• analysis of influence of quality of ingredients on quality of products.

The cost accounting on production

For the purposes of operational accounting of costs for productions and the analysis of a cost structure the software package Global Process Manufacturing provides following features:

• formation of planned calculations of product cost;
• operational assessment actually suffered material and labor costs on each batch of products with the subsequent their transfer to the module "Financial accounting";
• obtaining information on actual costs on the turned-out finished goods taking into account indirect and overheads from the module "Financial accounting";
• variance analysis between planned and actual cost of products;
• assessment of volumes of work in progress.

System of documentation

Some types of products should be followed by a set of the associated documentation on each turned-out (shipped) products. The software package Global Process Manufacturing provides following features on maintaining documentation on products:

• determination of the list of products of the requiring obligatory certification;
• determination of the list of dangerous materials;
• registration of a design and sending certificates for the shipped products.

Structure of interrelations with other system modules

The general structure of interrelations of Global Process Manufacturing with other system modules of Global can be presented in the following form:

• Reflection of information on the commodity and material movement
• The data on write-off in production (production) entered in works orders automatically are registered as the corresponding operations on a warehouse with change of a remaining balance on this warehouse. At write-off in production the size of a remaining balance on a write-off warehouse for the purpose of control of a negative balance is analyzed
• Data on personnel
• The list of production personnel, working schedules is also kept as a part of general information about personnel of the Global HRM enterprise.
• Data on repairs of the equipment
• If the software package Global Process Manufacturing is used together with the Global-EAM complex, information on the planned repairs and idle times of a production equipment is used when planning utilization of capacity and forming the production program.
• Data on labor costs
• If the software package Global Process Manufacturing is used together with the Global Salary complex, data on labor costs of production personnel in process of execution of works orders are transferred to a subsystem of payroll.
• Cost accounting
• The software package Global Process Manufacturing data about actual material and labor costs for calculation of actual cost of products are transferred to a subsystem Accounting and receives from this subsystem complete actual cost of the turned-out products taking into account the indirect and distributed costs.

Benefits from use of a management system for process production

• Process optimization of production planning
• Increase in rhythm of production.
• Decrease in volumes of work in progress.
• Increase in product quality.
• Optimization of operation of the replaceable equipment.
• Increase in speed of turnover of materials and money.
• Decrease in stocks of finished goods.
• Optimization of an order portfolio.
• Decrease in volumes of warehouse stocks.
• Decrease in an expense of Inventories on production.
• Reduction of runtime of orders.