Benefits

 

• Reduce Costs

• Improve Customer Relations

• Textile Industry Special Requirements

• Effective planning

• Detailed & Immediate Analysis & Controlling

• Provide Accessibility & Usability

• Decision Support Information

• Minimize discrepancy between the capacity of an organization and the demands of its customers.

• Provide better utilization of existing capacity (machines or labors).

• Better control of inventory management.

• Improved scheduling.

• Applying J.I.T concept in purchasing & production.

• Improve customer satisfaction

• Provide the final product in proper time , in propercost & in proper quantity .

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Production & Capacity Planning

Planning cycle

• Receiving demands (sales order – forecast – replenishment order.)

• Arranging the demands according to its priority.

• Distributing demand among resources.

• Appling J.I.T policy.

• Running M.R.P to determine demand’s requirements.

• Generating initial M.O. for each finished & semi finished demand.

• Determine start & end date for each initial M.O

• Load distribution among resources.

• User load manipulation.

• Generating more than one scenario.

• Approving M.O of one scenario.

• Issuing purchasing requisitions for needed R.M.

• R.M. reservation.

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Planning Components

• Calendars

• B.O.M

• Resources 

• Route

• Product planning

• M.P.S

• M.R.P

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B.O.M.

• Support multilevel B.O.M.

• Support multi B.O.M for the same product.

• Support scraps & yield handling.

• Support fixed Qty consumption.

• Support solution manipulation consumption.

• Support textile adaptations for consumption.

• (Consumption varies according to size & color).

• Support loss ratio for raw material.

• Raw materials distribution among different operations.

• Support alternative items.

• Copy B.O.M from B.O.M.

• 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

• Support more than one route for the same item.

• Support one route for multiple items.

• Support multiple operations.

• Support operation over lapping.

  • By time

  • By percent of time

  • By Qty

  • Parallel

  • Sequential

• Support various type of time for each operation.

  • Fixed

  • Variable

  • Capacity Influence

• Support out sourcing operations.

• Support operations instructions.

• Support automatic testing for the route

• Support Copy route from route

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Product planning

• Support multiple P.L.T for the raw material depending on vendor.

• Support fixed & variable P.L.T for each vendor.

• Support multiple routes & B.O.M for each semi finished & finished product depending on :

  • Customer

  • Customer destinations

• Support different types of order policy

  • Lot for order

  • Lot for model

    • Lot for lot

    • Lot for batch

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M.P.S

• Support forward & infinite capacity.

• Support collective sales order, forecast & replenishment plans.

• Support collective criteria according to

  • Customer

  • Document type (sales order, forecast, replenishment plan or all)

  • Period of time

  • Classification

• Support more than one scenario for the same criteria

• Support store group for materialmanagement.

• Support under receipt qty for material management.

• Support item / order selectivity

• Support 3 methods for calculating the start & end date

  • Planned

  • Just in time. ( J.I.T)

  • Just in time operation.

• Support scenario manipulation

• Support scenario manipulation

  • Deleting scenario

  • Approving scenario

  • Change start date

  • Change P.L.T

• Support graphical load over view.

• Support detailed analysis for overload reasons.

  • Support user color presentation for overload

    • On manufacturing order basis

    • On operation basis

  • Release raw material requirement report.

  • Release for each scenario start and end date for each M.Os according to 3 types.

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M.R.P

• Automatic or manual release for approved manufacturing orders.

• Automatic or manual reservation for raw material from stock upon user demand.

• Automatic or manual reservation for raw material from purchase orders upon user demand.

• Automatic or manual release for raw materials requisitions.

• Automatic or manual release for outsourcing requisitions.

Production Control (Shop Floor)

Shop Floor Features

• Fully integrated with AL MOTAKAMEL inventory system.

• Fully integrated with AL MOTAKAMEL Quality control system.

• 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.

• Ability to link an inventory issue or return note with the costing module.

• Ability to cost the finished good receiving note of a manufacturing order without physical posting of inventory module.

• Ability to issue raw material for manufacturing order not included in the B.O.M under security permission.

• Support good treatment for reproducing manufacturing order.

• Support lot tracing capabilities.

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Production Costing

Costing module features

• User defined cost elements.

• User defined productive cost center & servicing cost centers.

• User defined cost center budget.

• User defined distributing ratio of servicing cost centers on productive cost centers.

• Ability to estimate production cost of any product before production.

• Ability to analyze production cost of any product to its cost elements.

• Comparing estimated cost with actual cost from different point of views

  1. Raw Material   (quantity – value)  

  2. Working hours   (Number & values)

• Comparison can be applied on

  1. Manufacturing order

  2. Products produced

  3. Cost center

• 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.

• Fully integrated with ALMOTAKAMEL inventory system

• Creating costing entries upon user request

• Closing manufacturing order upon user request ( temporary – permanent )

• Comprehensive method for work in progress treatment.

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Quality Management

• 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

• Features

• Equipment full detailed information including purchase , manufacturing ,parts , counters , meters , catalogs and operatingcautions & instructions .

• Maintenance tasks describing estimated/shutdown/standby times , needed tools , materials , spare parts ,laborand executions instructions to optimize the achievement of maintenance services.

• Maintenance routines describing maintenance Service which categorize , group and order maintenance tasks.

• Inspections routines includes equipment checks , inspection tasks , instructions , labor ,materials

• Equipment Monitoring transactions to monitor equipments operation conditions and performance in order to Avoid unexpected equipment failures.

• 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.

• Supporting casual/sudden maintenance Requests.

• Maintenance Queue managements which enable maintenance manager to approve, hold, cancel... any scheduled maintenance or inspection routine.