Manufacturing Suite
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Production & Capacity Planning
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Production Control (Shop Floor)
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Production Costing
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Quality Management
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Preventive Maintenance
Benefits
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Reduce Costs
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Improve Customer Relations
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Textile Industry Special Requirements
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Effective planning
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Detailed & Immediate Analysis & Controlling
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Provide Accessibility & Usability
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Decision Support Information
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Minimize discrepancy between the capacity of an organization and the demands of its customers.
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Provide better utilization of existing capacity (machines or labors).
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Better control of inventory management.
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Improved scheduling.
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Applying J.I.T concept in purchasing & production.
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Improve customer satisfaction
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Provide the final product in proper time , in propercost & in proper quantity .
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Production & Capacity Planning
Planning cycle
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Receiving demands (sales order – forecast – replenishment order.)
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Arranging the demands according to its priority.
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Distributing demand among resources.
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Appling J.I.T policy.
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Running M.R.P to determine demand’s requirements.
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Generating initial M.O. for each finished & semi finished demand.
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Determine start & end date for each initial M.O
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Load distribution among resources.
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User load manipulation.
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Generating more than one scenario.
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Approving M.O of one scenario.
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Issuing purchasing requisitions for needed R.M.
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R.M. reservation.
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Planning Components
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Calendars
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B.O.M
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Resources
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Route
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Product planning
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M.P.S
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M.R.P
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B.O.M.
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Support multilevel B.O.M.
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Support multi B.O.M for the same product.
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Support scraps & yield handling.
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Support fixed Qty consumption.
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Support solution manipulation consumption.
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Support textile adaptations for consumption.
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(Consumption varies according to size & color).
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Support loss ratio for raw material.
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Raw materials distribution among different operations.
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Support alternative items.
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Copy B.O.M from B.O.M.
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Support validity period & activation flag.
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Resources
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Features
1- Multi level Manufacturing Resources (machine – labor – tool).
2- Capacity by Units or Time.
3- Multi calendars for the same resource
4- Multi shifts for the same resource.
5- Resource User Defined Attributes.
6- Utilization and Efficiency Percentage for Every Resource.
7- Support outsourcing resource.
Route
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Support more than one route for the same item.
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Support one route for multiple items.
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Support multiple operations.
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Support operation over lapping.
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By time
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By percent of time
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By Qty
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Parallel
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Sequential
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Support various type of time for each operation.
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Fixed
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Variable
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Capacity Influence
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Support out sourcing operations.
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Support operations instructions.
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Support automatic testing for the route
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Support Copy route from route
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Product planning
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Support multiple P.L.T for the raw material depending on vendor.
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Support fixed & variable P.L.T for each vendor.
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Support multiple routes & B.O.M for each semi finished & finished product depending on :
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Customer
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Customer destinations
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Support different types of order policy
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Lot for order
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Lot for model
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Lot for lot
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Lot for batch
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M.P.S
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Support forward & infinite capacity.
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Support collective sales order, forecast & replenishment plans.
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Support collective criteria according to
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Customer
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Document type (sales order, forecast, replenishment plan or all)
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Period of time
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Classification
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Support more than one scenario for the same criteria
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Support store group for materialmanagement.
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Support under receipt qty for material management.
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Support item / order selectivity
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Support 3 methods for calculating the start & end date
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Planned
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Just in time. ( J.I.T)
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Just in time operation.
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Support scenario manipulation
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Support scenario manipulation
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Deleting scenario
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Approving scenario
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Change start date
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Change P.L.T
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Support graphical load over view.
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Support detailed analysis for overload reasons.
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Support user color presentation for overload
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On manufacturing order basis
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On operation basis
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Release raw material requirement report.
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Release for each scenario start and end date for each M.Os according to 3 types.
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M.R.P
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Automatic or manual release for approved manufacturing orders.
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Automatic or manual reservation for raw material from stock upon user demand.
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Automatic or manual reservation for raw material from purchase orders upon user demand.
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Automatic or manual release for raw materials requisitions.
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Automatic or manual release for outsourcing requisitions.
Production Control (Shop Floor)
Shop Floor Features
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Fully integrated with AL MOTAKAMEL inventory system.
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Fully integrated with AL MOTAKAMEL Quality control system.
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Ability to create requisition for issuing or returning raw material from the costing module to be transferred to an issue or return note upon inventory user request.
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Ability to link an inventory issue or return note with the costing module.
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Ability to cost the finished good receiving note of a manufacturing order without physical posting of inventory module.
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Ability to issue raw material for manufacturing order not included in the B.O.M under security permission.
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Support good treatment for reproducing manufacturing order.
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Support lot tracing capabilities.
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Production Costing
Costing module features
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User defined cost elements.
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User defined productive cost center & servicing cost centers.
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User defined cost center budget.
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User defined distributing ratio of servicing cost centers on productive cost centers.
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Ability to estimate production cost of any product before production.
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Ability to analyze production cost of any product to its cost elements.
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Comparing estimated cost with actual cost from different point of views
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Raw Material (quantity – value)
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Working hours (Number & values)
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Comparison can be applied on
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Manufacturing order
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Products produced
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Cost center
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Ability to produce different products on the same manufacturing order and user can distribute the cost between these products on per defined setup ratio with ability to modify.
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Fully integrated with ALMOTAKAMEL inventory system
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Creating costing entries upon user request
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Closing manufacturing order upon user request ( temporary – permanent )
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Comprehensive method for work in progress treatment.
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Quality Management
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Features
1- Different Quality Elements:
A- Fixed List (Verified By User).
B- Number (With MIN,MAX& Target For Result Auto Creation).
C- Text.
D- Date.
E- Formula (Calculate From Other Elements).
2- Special Quality For Customer And/Or Product.
3- Supporting Four & Six Points Systems.
4- Quality Plan & Inspection For Product Processing Operation.
5- Automatic (According To Defined Formula) Or Manual Quality Result.
6- Stock Transactions Quality.
7- Lot Tracking.
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Preventive Maintenance
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Features
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Equipment full detailed information including purchase , manufacturing ,parts , counters , meters , catalogs and operatingcautions & instructions .
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Maintenance tasks describing estimated/shutdown/standby times , needed tools , materials , spare parts ,laborand executions instructions to optimize the achievement of maintenance services.
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Maintenance routines describing maintenance Service which categorize , group and order maintenance tasks.
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Inspections routines includes equipment checks , inspection tasks , instructions , labor ,materials
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Equipment Monitoring transactions to monitor equipments operation conditions and performance in order to Avoid unexpected equipment failures.
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Planning Master Schedule which schedule the maintenance and inspections routines supporting time (weekly, monthly, etc.), meter (hour meter ,heat meter, etc.) andcounter (piece counter ,etc.) based planning.
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Supporting casual/sudden maintenance Requests.
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Maintenance Queue managements which enable maintenance manager to approve, hold, cancel... any scheduled maintenance or inspection routine.