Merkator Kaluga (IsWMS)

Tasks

The Merkator company made the decision to upgrade business processes of formation of purchase orders of parts and nodes, warehouse processing and, the most important, process of production assembly of products for the purpose of exact control and process control of lean production, reducing costs of a trade inventory, cost reduction on process of preparation and tracking of accomplishment of orders, and also a production process. Any violation of the diagram in the scheme of "lean" production can lead to a production process stop.

For implementation of the tasks, the Merkator company selected the IsWMS system with the module MES (industrial process control) of InStock Technologies company

Solution

The project is decided to be separated into three phases.

The following functionality is implemented into the first phase:

System implementation of management of receipt, storage and use of parts and materials, and also finished product output at the plant in Vorsino, including:

• The interface of formation of the formalized technical order for a product on the basis of unformalized customer requirements
• Formation of orders for order-based materials on a product (on the basis of technology specifications of products) and on the basis of a material remaining balance on a production line
• Intake of materials and spare parts on a warehouse, barcoding of goods
• Distribution of materials in a production zone
• Tracking of the statuses and production process of products on a production line (including, graphically visualized)
• Write-off of materials is performed in this phase after completion of assembly of unit of finished goods
• Feed of production on the basis of min|max
• Genealogy of Finished Goods: In a System there is information on structure of each unit of GP.
• Inventory of segments of production lines
• Return of unspent materials from production zones on a warehouse
• Integration with corporate systems of the enterprise

Short process description as a result of implementation of the first project phase:

The manager creates in a system the formalized order for a product, on the basis of the preliminary descriptive customer order. At the same time, a system uses information on possible compatibility of these or those components of a product and limits the choice of the manager on the basis of the components selected earlier.

At order launch in processing, a system creates the list of parts and component parts which will be used by production, and, being guided by a warehouse stock, creates data for orders to the corresponding suppliers of parts/materials.

When the goods arrive on the plant, a system manages acceptance and distribution of goods to a warehouse or directly in cells of a production line. The necessary goods (parts and materials) go to each cell.

A system writes off parts and materials in process of their installation for a product, I fix product genealogy: what parts and what materials of batches were used by production of this or that copy of a product.

In a system all necessary operations on accounting, replenishment and inventory of parts and materials in a warehouse and production are executed.