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Streamline Your Production with myNexgen ERP Solutions

Discover how myNexgen ERP from Nexgen Infosystems Private Limited revolutionizes production processes. Our comprehensive tools facilitate effective resource planning, capacity management, inventory control, and seamless integration with sales forecasting and analysis. With features such as recipe management, alternate recipe handling, and lot traceability, businesses can ensure compliance and optimize production workflows. Experience enhanced scheduling options and cost tracking capabilities that align with industry standards. Embrace a smarter, more efficient way to manage your production and logistics.

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Streamline Your Production with myNexgen ERP Solutions

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  1. myNexgen ERP Production Process NexgenInfosystems Private Limited

  2. myNexgen ERP Complementary Products Tools & Utilities Sales Sales Forecast & Analysis Sales Order Shipping Discrete Production Product Definition Planning & Execution Engineering Change Control Human Resources Personnel Benefits Payroll Training Financials Accounts Receivable Accounts Payable Fixed Assets General Ledger Mgmt. Accounting Maintenance Equipment Maintenance Operations Logistics Inventory Purchasing Physical Inventory & Cycle Count Sub Contracting Administration

  3. Roadmap • Advantages • Core Concepts • Core Processes • Key Features • Integration • Benefits Advantages

  4. myNexgen ERP Process Production • Effective planning of resources • Capacity • Material • Meets statutory requirements • Lot traceability • Expiry dates etc... • Recipe / formula management • Alternate recipes • Attribute handling • Global change

  5. myNexgen ERP Process Production... • Links demand to sales and tracks progress of such production orders • Flexible • Planning options • Scheduling options • Allocation and picking options • Tracks costs at all stages of production • Nomenclature conforms to ISA S88 standard for batch production

  6. Core concepts • Configuring (modeling) • Measurement ID • Recipe   

  7. Process stage Planning Recipe Process Center Production Recipe Resource Process unit Accessory Human Resource Parameter Modeling

  8. Process unit Loading group Input / Output Parameter Resources Human Resource Accessory Modeling... Multi Process center

  9. Process Network Modeling... • Process stages linked using primary output defined Process stage 1 Process stage 3 Process stage 2 Process stage n Process stage 4 Process stage 5

  10. Pressure Measurement ID(MID) • MID is a combination of a process unit and parameter Measurement ID (MID) 1 Process Unit 1 Material Flow Temperature

  11. Recipe • Provides levels of recipe • Planning recipe - for MRP • Production recipe - for production • Production order recipe • Attribute based quantity determination (potency / assay) • Handles co-products / by-products • Enables recycling • Process parameters at recipe level • Global change

  12. Sales order & Forecast Eqp 1 Eqp 3 Modeling Shipping Eqp 2 Planning Purchase PRs & SCRs Aug 4 Scheduling Inventory Shop floor, execution & control To shop floor Core processes

  13. Core processes... • Planning • Execution • Analysis   

  14. Sales Ord.1 --- --- --- --- --- --- 1600 1600 Purchasing 1600 1200 jan feb mar apr Planning Salesforecast Salesorder Seasonalbuild • Calendar Productionschedule RCCP • BOM • Routing • PO rules Firmedproductionorder MRP

  15. Rough cut capacity planning (RCCP) • Long-term capacity planning • Flexible planning horizon / periods • Projects capacity load profile based on forecast / orders • Aids in identifying bottlenecks

  16. Planning parameters • Production order rules • Order policy : POQ, LFL, FOQ • Minimum order, maximum order qty • Order multiple • Optional production order against forecast • Multiple sources of supply

  17. Demand Firmedsupply Stockon hand Seasonalbuild MRP Exception Messages ! • BOM • Batch size • Disposition • Sources of supply • Prod. order rules Net Requirement 70 60 50 40 30 20 10 0 Per. 1 Per. 2 Per. 3 Per. 4 Productionorder Subcontractrequest Purchase request MRP

  18. 100 80 60 40 20 0 Per. 1 Per. 2 Per. 3 Per. 4 Sources of supply NET REQUIREMENT Year : 1998 Period : 3 Net requirement : 100,000 units 50% 20% 30% Sources of supply Purchased Manufactured Subcontracted 50,000 units 20,000 units 30,000 units

  19. To shop floor To shop floor To shop floor Available capacity Maintenanceschedule 30 20 10 0 PU 4 PU 1 PU 2 PU 3 ! Finite schedule Aug 4 Finite scheduling Production order release Firm reserved production Order • Prd ord amendment • Schedule constraints • Prd ord - recipe change • Prd ord - scheduling option NO YES YES Material Reservation Capacity exceptions Scheduled Production Orders NO Material exceptions

  20. Finite scheduling... • Finite backward / forward scheduling • Optional material reservation check • Displays capacity and material exceptions • Specify production order level capacity constraints • Optionally amend production order recipe, quantity and due date • Hold production orders

  21. Finite scheduling...Rules • Finite scheduling - user-defined rules • Scheduling method : forward / backward • Load splitting • Partial loading • Overlapping • Combining orders (multi process center) • Order priority • Process units - deployment rules • Horizon step

  22. 1 Finite scheduling... ? 1 PS 1 PS 2 PS 3 2 2 3 3 Today Time Already loaded Backwardscheduling Forward scheduling to define new end date

  23. To shop floor Shop floor execution & control Production order release Hard allocation  Process stage, execution & ctrl. Quality clearance Movement to inventory Close/short close production order Shipping SPC / SQC

  24. Hard allocation • Methods • LIFO • FIFO • Max. zone bin • Min. zone bin • Expiry date • Attribute based • User-defined

  25. Hard allocation... • Scale up based on lot level attribute value (potency / assay) • Picking based on multiple attributes • Allows bulk / automatic allocation • Provision to de-allocate and reallocate • Generates pick sheet based on options specified

  26. Production order Release • Indicates material availability for reservation to Ramco Sales • Enables Ramco Management Accounting to track costs for the production order

  27. Production orderExecution and control • Executes different process stages for a order, captures data on • Batch details • Material production and consumption • Human resources / accessory deployed • Costing activity details • Stoppage details • Enables QC clearance of produced items and movement to storage / warehouse

  28. Production orderCosting • Activity based costing • User-defined costing activities • Tracks manpower, machinery and accessory costs

  29. Production orderClose / short close • Order settlement in Ramco Management Accounting • De-reserves stocks, capacity on short closure • Passes information to Ramco Sales if production order - sales order link exists

  30. Analysis • Rough cut capacity analysis • MRP summary • Raw material requirement analysis • Finite scheduling - scheduling chart • Capacity / material exceptions • Costing analysis - cost sheet

  31. Analysis... • Online process parameters analysis • Quality clearance (QC) analysis • WIP inventory analysis • Lot tracking • Where-used analysis

  32. Key features • Integration with process control systems • Multi-process unit • Production order life cycle • Production order decoupling • Raw material (RM) availability check • Backflushing • Lot tracking • Where-used analysis        

  33. Integration with process control systems Ramco PP Process Unit Parameter Measurement ID Interface DCS

  34. Fisher Process control information architecture • Windows 3.1 • Windows 95 • Windows NT • Client applications Ramco Business management Real Time Integrator (RTI) • Windows NT • Operator console • RT/ history data • Server Plant highway • Windows NT • RT/ history data • Server • Windows NT • Operator console Plant highway Process management Fieldbus Controller Field management • Measurement • Pressure • Temp • Flow • Level Coriolis • Analytical • Simple • Complex HandheldPDA • Analog I/O • Digital I/O • TC/RTD Configuration &maintenance PD metersCommon head Valvespositioners

  35. Multi-process unit Input 2 Input 3 Input 1 Multi-Process Unit Output 2 Output 3 Output 1 • Simultaneous process of multiple items • Loading group • Continuous / batch • Capacity factor Product 2 Product 3 Product 1

  36. Firm Up Firmedproduction order Plannedproduction order MRP Manually created Firm scheduled production order Schedule Scheduled production order Firm Schedule Short close /close production order Hold Released order Complete production Production order life cycle Release

  37. Production order decoupling Production Order 1 Process stage 1 Process stage 2 Process stage 3 Rawmaterial Intermediate 3 Decouplingpoint Production Order 2 Process stage 4 Process stage 5 Process stage 6 Finishedgoods

  38. MRP run Scheduling MRP Reservation PR Execution Exception messages Firm reservation Allocation Exception messages Production execution Hold prd ord RM availability check

  39. FG 1 100 units (Reporting produced quantity) Input item Qty req. Qty alloc. Qty issued Qty consumed RMIXT 200 200 200 200 RM2YC 50 50 50 50 - - RM3BF 100 100 RMXB1 70 70 70 70 Backflushing Finished goods Details • Updates Ramco Inventory automatically based on reported consumed quantity Recipe

  40. Inter 1 Lot Y232 Inter 2 Lot Y232 Inter 3 Lot Y232 RM 1 / 001 /198 / M1 RM 4 / 001 /198 / M1 RM 5 / 001 /198 / M1 RM 2 / 002 / 198 M1 RM 3 / 002 / 198 M1 RM 6 / 002 / 198 M1 Lot tracking FG – LOT XY0001 Drilldown from FG lot level to the lowest detail level RM - Raw material Inter - Intermediate FG - Finished goods

  41. Where-used analysis RM 3 / 0000001/98/M1 • Displays FG lots which have consumed a particular raw material lot FG 1 Lot 001/198 FG 2 Lot 002/198 FG 3 Lot 003/198

  42. Sales Inventory & Purchase Ramco Process Production myNexgen ERP Process Production • Sales forecast & orders • Sales order-production order linkage • Item details • Reservation • Hard allocation • Issues & receipts • Purchase requests SPC/SQC General Ledger & MAC • Production reporting • In-process analysis • QC clearance • Financial postings • Cost Centers • Activity cost element • Activity std. rates • Order / batch costing

  43. PP myNexgen ERP Process Production... Ramco Process Production Maintenance RTI • Equipment details • Preventive maintenance schedules • Maintenance forecast • Run hour updation • Work request • Capture Process parameters • Item consumption / production details

  44. myNexgen ERP Process Production • Eliminates supply chain bottlenecks due to integration with other Ramco applications • Planning and scheduling systems enable effective inventory management • Improved product cost visibility • Integrates with process control systems

  45. Roadmap • Advantages • Core Concepts • Core Processes • Key Features • Integration • Benefits

  46. Thank you

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