WIXLIB

Production Managementthrough manufacturing center transactions.The data you capture through this processcan then be analyzed as needed against anylean performance metrics you define.Lean MetricsIndicate lean metrics by period, day, week,resource group, even free form parameterssuch as seasonal. Use the Production Activitytracker to dynamically evaluate the productionactivity for each resource group againstthe lean performance metrics you haveestablished for your manufacturing processes.Support for Hybrid Approachesto LeanEmploy a phased approach to implementinglean practices for tracking material, MRPand Kanban in a mixed environment. Byoffering manufacturers the choice, at thepart location level, how the part will beFigure 7.2 Manufacturing Execution System—Automatically collect and report the status of Jobsmanaged, manufacturers can more easilyon the plant floor in real time.migrate to lean, while synchronizing MRPand Kanban execution.triggered for replenishment as needed withreal-time stock replenishment Kanban usingreal-time manufacturing Kanbans. Insteadautomatic triggering of stocked inventory.of planning for each order that is processed,(See figure 7.1)parts are pulled through production asReal-time Purchase Kanbaninventory or cell stocking levels fall belowUse the real-time purchase Kanban toManufacturing ExecutionSystemminimums. The cell is visually queued toreplenish directly from the supplier andMES is an easy-to-use, online system forproduce based on the Kanban quantity fornotify purchasing that a stock replenishmentthe plant floor that allows plant-basedthe part at its warehouse, bin oris required. Automatically send an e-mail totransactions real-time visibility throughoutcell location.the supplier requesting additional inventorythe Epicor solution. Epicor MES enablesagainst an open purchase contract.accurate labor reporting, as well as onlineManufacturing Flow KanbanInventory can be received to the maintransaction tracking, which providesView future demand to dynamicallystores, or directly to the production floor.management with a real-time picturecalculate future replenishment Kanbans withReal-time purchase Kanban automates theof what is occurring on the plant floorthe manufacturing flow Kanban. This givesreplenishment of material from vendors andby employee and job. Integration withdownstream cells and suppliers visibility ofprovides for visibility of currentEpicor Job Management, Scheduling,future demand (although the actual Kanbansupply requests.Quality Assurance, and Advanced Materialevents may differ during execution). AsManagement eliminates dual entry andKanbans are acted on, the downstreamAutomated Material Flowprovides online, real-time views of thedemand requirement is dynamicallyAuthorize supplying cells to make alatest plant floor scheduling priorities. Inupdated. All cells and suppliers have up-to-predefined quantity of an item beingaddition, an integration with the Epicordate visibility of future demand.“pulled“ by using operations.Document Attach Tool allows plant flooraccess to needed documentation, suchReal-time Stock ReplenishmentKanbanMove inventory as it is needed in a particularMeasurement of ProductionActivity Against LeanPerformance Metricsmanufacturing cell, shipping area orUse the Production Activity function tocustomer consignment location with thecapture production data automatically6as product drawings, process documents,and multimedia videos. Complete modulefunctionality includes:

Production ManagementFlexible Data Entry TechnologyTrackers in the Plantdata and the ability to eliminate inaccurateUse touchscreen, mouse, bar code,Users can access online trackers on theand time-consuming manual data collection;or keyboard interface to update laborplant floor from within MES. Job Tracker,so operators can stop measuring andinformation from the plant floor. EliminateOrder Tracker, Customer Tracker, Shipmentmonitoring, and focus on makingdata entry mistakes and increase transactionTracker, and more are available based onquality products.speed by simply scanning a bar code tag tologin and secure access. Shop Tracker showscomplete a transaction.who’s here, who’s not here, current workYou can achieve informed lights outcenter activity, as well as user-defined alertmanufacturing, and get the powerfulconditions from the plant floormetrics you need to improve performance–Work QueueProvide employees with prioritized workOverall Equipment Effectiveness (OEE), runschedules and make information directlyShipping and Receivingrates, scrap, yield, energy consumption,available to the plant floor. MES is optimizedIn combination with the Advancedmaterial consumption, and much more.for use on the plant floor with the ability toMaterial Management module, maximizeAccurate machine-related data, alongselect multiple operations for work at theresponsiveness in the warehouse withwith operator depth and dimension helpssame time, full sheet views, views specificShipping and Receiving functions fromyou pinpoint critical issues, reduce waste,to current, available, or expected work,within MES.and improve quality and customer service.ability to target work based on TAKT, pieces,Advanced MES functionality includes:hours, and setup group designations, andInventory Managementadvanced search capabilities.In combination with the AdvancedDeploy Your WayMaterial Management module, maximizeEpicor makes it easy to get there– AdvancedMultiple Languagesresponsiveness in the warehouse withMES runs on current Microsoft WindowsDisplay the Manufacturing Execution SystemInventory functions such as adjustment,Server with SQL Server. Epicor Advancedscreens in the employee’s primary language.material issues, physical inventory countsMES has the industry know how to connectfrom within MES.to or get a signal from any kind of machine,Distributed Hoursno matter how timeworn or modern, andAutomatically split labor hours acrossMaterial Handlingthe system uses machine interface unitsmultiple jobs being worked onIn combination with the Advanced(MIUs), open connectivity protocol (OPC),simultaneously by an employee. Likewise,Material Management module, maximizeprogrammable logic control (PLC), andsplit resource or machine hours when two orresponsiveness of material handlers withpersonal computer (PC) interfaces.more employees work on the same resource.material move queues and give operatorsthe ability to request in-process WIP movesUsabilityQuality Reportingof product from one location to another,Advanced MES collects production dataCapture rework and scrap reason codes, alongmaximizing control of in process productsautomatically—no more manual datawith miscellaneous employee comments fromwhile reducing delays. Additionally, movecollection to worry about. Operators usethe plant floor. Use the Quality AssuranceWIP products into inventory storagetouch-screen technology to add depth andoptions to report setup inspection, first article,locations or stage WIP at the next resourcedimension to the automatic productionpiece counts, and more.based on available space and time. Quicklydata, so you get a clear picture of theand accurately identify WIP and inventorywhat, why and when of downtime, cycleShop Warningscontainers with system generated bar codes.time, quality, and scrap. Operator help callsShop warnings appear in various locations(See figure 7.2)with automatic routing and notificationsthroughout the system when certainempower employees to respond quickly,conditions exist or certain events occur. Theyimproving productivity.are intended to keep supervisors informed ofa job’s status or an employee’s performance.Advanced MES (EpicorMattec )Plant NotificationAdvanced MES (Epicor Mattec The system also has real-time automatedGrace Periods/Multiple ShiftsManufacturing System) extends your Epicoralerts, notifications, escalation and otherManage clock-in and clock-out periods withsystem to provide automatic productioncommunications, so the people who needadjustments made for user-defined grace periods.monitoring and process monitoring,to know are in the know when it mattersAccommodate split and staggered shifts.empowering manufacturers with productionthe most—immediately, so they can take7

Production Managementaction to correct a problem, or improveSome examples include:improves as a result of this collaboration.performance on-the-spot. Automated alerts Injection pressuresQuality no longer needs to be an isolatedinclude machine conditions, cycle, process Opening/closing speedsdepartment. In collaboration withvariations, efficiency, and scrap. Barrel/mold temperaturesengineering, production, and sourcing, Multiple locations/zonesquality naturally improves. Cost of quality isOffice, Mobile, and GlobalTake the power of Advanced MES withyou on a Web-enabled mobile device orXX Users can clear the Advanced MESalso reduced dramatically.schedule from Epicor ERP.XX Support for Advanced MES ResourceMobile Qualitytablet with browser-based dashboards,Groups in the process sheet simplifiesAccess to information at the point ofinformation, and analysis. Plus, it doesn’tpart engineering for users.checking and recording quality eventsmatter if you have a single operation, or aXX To better control information goingreduces inaccuracies and improves efficiencydistributed network of plants internationally,to Advanced MES, users can limit theof quality professionals. Whether they arethe system is currently available in more thannumber of operations exported torecording inspection results or responding10 languages, and suitable forAdvanced MES.with root cause analysis to a correctivelanguage customization.Schedule OptimizationNote: For information on Mattec Analytics, referaction, information about quality that isto the “Business Intelligence and Analytics”inclusive and tied throughout the businesssection.improves overall business quality.Advanced MES helps the plant changeinstantly based on new requirements with aInspection Workbenchclick-and-drag production schedule. Or, youQuality Assurancecan watch the schedule update and adjustExtending your solution with the Qualitypriority and automatically take action onautomatically based on actual machineAssurance module ensures that youthose requirements from the inspectionspeeds, production counts, equipmentgain complete visibility into your qualityworkbench. Inspectors move passed partsstatus, conditions, or job specifications. Theoperations from a top-down view down toback to jobs and failed parts into discrepantsystem makes it easy to plan by showingthe individual item level, allowing you to tiematerial report (DMR) processing, or theyresource availability based on machine/ part/together all quality functions, whether it’ssimply scrap them.tool compatibility, and optimal plans basedscrapping end parts, rejecting raw materialson prior part performance. What-if analysisor tracking first article inspections. AccurateNonconformant Recordscombines with built-in machine capacitycosting demands that products movedCreate a nonconformant record (NCR) forplanning and labor and material forecastingthrough quality accurately reflect their valueall nonconformant parts. From a job, shopfor better planning. Advanced MES supportsand are removed from the appropriate workfloor employees automatically create anKanban scheduling.in progress.NCR when they scrap an end part or rawAdvanced MES Integration toEpicor ERPAdditionally, Quality Assurance includesEnhanced integration improves the efficiencyto Accounts Payable for automated debitNon-Netting Binsand ease-of-use for Advanced MES withprocessing—closing the loop on traceabilityUse non-nettable bins to keep partsEpicor ERP software. Key integrationof products in and out of quality withinundergoing inspection or on-hand quantities.points include:the plant. Inspectors have queues ofMonitor WIP, review all inspections inmaterial. Inventory personnel create an NCRwhen they scrap parts from inventory.processes for supplier returns with linkscorrective action follow-up, while plantDiscrepant Material ReportProcessingthe Pieces per Cycle operation standardsfloor employees can easily flag partsAfter failing inspection, create a DMR toused in Mattec MES.as nonconformant. Quality Assuranceprovide the MRB with an online queue offunctionality includes:parts that need to be dispositioned.production planners to keep track ofSocial QualityCorrective Actionmachine parameters in both Epicor ERPCollaboration among the right resourcesCreate and track all preventive andand Advanced MES. This offers a singleto improve quality often means redundantcorrective actions online. With due dates,point of engineering definition thatcommunication and events. Using socialaudit sign-offs and unlimited comments,resides in Epicor ERP.quality groups enables quality events tocorrective actions provide for follow-up ofbe resolved faster, and long term qualityquality issues.items to inspect with full disposition andXX The Epicor ERP user interface includesXX Epicor ERP offers support for machineparameters that can be used by8

Production ManagementInspection PlanBuild inspection plans that utilizespecification lists and inspection attributes.Define unique business inspection attributesor characteristics. Attributes can be numeric,character, date, check box, combo box,or comments. Sets of attributes definetest plan inputs with additional criteriaincluding minimum and maximum valuesexpected as well as combo box choicesand document attachments. For optimumcontrol, each specification list is revisioncontrolled. Inspection plans use embeddedconfiguration capabilities to build inputscreens tailored to each unique test planFigure 7.3 Quality Assurance—Record and track quality data to fulfill customer requirements andand lay out fields and data to matchpromote continuous improvement.quality department expectations. Defaultdocuments can be tied to the inspectionMaterial Review Board(COQ), or Certificates of Compliance. Toplan. For optimum control, each test plan isDisposition parts by an MRB after they failhelp manage this documentation, Epicorrevision controlled.inspection. Online documentation providesincludes the ability to check for Certificatesan audit trail of MRB actions.of Compliance at receiving of materials fromsuppliers, receiving of in process parts fromFlexible Inspection PlanConfigurationCost of Qualityoutside operation suppliers, and beforeIn addition to the dynamic nature of theGenerate cost of quality reports to identifyshipping products to customers.inspection plan (i.e. results entry formhow much quality problems are costing you,(See figure 7.3)is dynamically built based on the tiedwhether parts are scrapped from inventory,specifications list), multiple inspection plan/a job or receipt inspection.specification lists sets can be tied to a part,Packing SlipsEnhanced QualityAssurancePrint a customizable packing slip for allTraceability and audit of quality data drivesplans to sit alongside product or productparts returned.businesses to develop “systems,” manygroup specific test plans with results entry andtimes paper based, to support the collectioncollection of data for both during inspection.operation, or equipment. This flexibilitysupports requirements for standardized testDebit Memosand use of quality testing data. EnhancedCreate a debit memo in DMR processingQuality Assurance is designed to extendFlexible Results Collectionand it is automatically tied tobase Quality Assurance with support for theCollect and store results data for eachaccounts payable.management of controlled test plans andsample alongside appropriate job, part,the results for products, groups of products,inspection plan, serial number, lot number,processes, and other testing.purchase order data, and more. ResultsAudit TrailsView inventory transaction detail occurringdata can be used to produce compliancein inspection and DMR processing with theIt offers the ability to define testing elementsdocumentation and is available for auditmaterial transaction detail report.or attributes as well as lists of attributes to testpurposes on-line through the Inspectionwhich can be used to measure against testingResults Tracker.Certificates of Complianceresults for pass/fail decision criteria. It includesBusinesses are increasingly requiring detailedthe data used for Statistical Process Control (SPC)Support for Inspection Typescompliance documentation. Dependingand is easily accessed to build SPC analysis. InMake first article inspections and store resultsupon the industry, this documentationessence, Enhanced Quality Assurance gathersfor audit and analysis. Tie inspection plan/is commonly referred to as Certificatesthe data and makes it available to ensure thatspecification combinations to an operation toof Analysis (COA), Certificates of Qualityyour next audit goes smoothly.trigger results entry for the operation during9

Production ManagementAdvanced QualityManagementEpicor Advanced Quality Management(AQM) provides the foundation forsignificant productivity improvementsand cost reductions across your entireenterprise. It unifies the tools for qualityprocesses, thus streamlining compliancefor ISO 9001, ISO 13485, AS 9100, IATF16949, and more. At its core, AQM servesas the hub for everything related to qualitymanagement. AQM yields actionableinsight into performance, cost of qualityand risk-related metrics including real-timevisibility on supplier quality, production andcustomer satisfaction. AQM is an enterprisequality management solution that actsFigure 7.4 Enhanced Quality Assurance—Track inspection results data online.as your intelligence gateway into globalperformance, delivering objectively andtruthfully, the who, what, where, whencollection of data on the plant floor. Performcourses to attend or can request trainingand why of all things quality. Reportingreceiving inspections on parts subcontracted tothemselves. Review employee training withand analytics are built into the AQMa specific supplier. Track results and generatethe Training Course Tracker for proof ofsolution. On-the-fly data visualization andsupplier performance metrics with data fromcertification to perform work.deep analysis of multiple measures, acrosssample results.different processes for all levels of theReal-Time Quality Analysisenterprise is included. The complete web-Skip Lot Cycle DefinitionsWhether responding to a bad test resultbased solution includes these modules:Optionally categorize and setup cycles forimmediately with Business Processreceiving inspection with skip lot logic thatManagement (alerting a quality managerXX Product Managementfollows optimum frequency of inspectionsabout a critical result), performing trendsXX Nonconformancefor suppliers. Whether inspecting all lots oranalysis or responding to an auditor requestXX Corrective Actioninspecting one and skipping the next tenwith data pulled from a Business ActivityXX Customer Managementlots, skip lot ensures that quality controlQuery or reviewing supplier performanceXX Supplier Qualitymanages the frequency of inspection.utilizing analysis cubes and dashboards. AllXX Document Controlthe data you need is available with a robustXX Audit ManagementResource Calibration Test Planstool set to support your unique businessXX Risk ManagementUsed in conjunction with Epicorrequirements.XX CalibrationXX MaintenanceMaintenance Management, EnhancedQuality Assurance offers the ability toComplete functionality includes:XX Inspection/SPCXX Quality Planningpredefine inspection plans for resource(gauge) calibrations along with managingXX Statistical Process Control (SPC) dataXX Trainingthe last calibration date.XX Returned Material AuthorizationXX Supplier PortalTraining Course ManagementXX Manufacturing execution(RMA) inspectionManage employee training events forsystems enabledboth onsite and offsite training, includingXX Serial and lot traceabilitymanagement of training costs. AssignXX Inspection collect results locationinstructors and set schedules for courses.XX Inspection Data TrackerEmployees can be assigned appropriate(See figure 7.4)10

Production ManagementAbout EncompassEncompass Solutions is a business and software consulting firm that specializes in ERP systems, EDI, and Managed Servicessupport for Manufacturers and Distributors. Serving small and medium-sized businesses since 2001, Encompass has helpedmodernize operations and automate processes for hundreds of customers across the globe. Whether undertaking full-scaleimplementation, integration, and renovation of existing systems, Encompass provides a specialized approach to every client’sneeds. By identifying customer requirements and addressing them with the right solutions, we ensure our clients areequipped to match the pace of Industry.Contact us e contents of this document are for informational purposes only and are subject to change without notice. Epicor Software Corporation makes no guarantee, representations, or warranties with regard to theenclosed information and specifically disclaims, to the full extent of the law, any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality, or reasonable skill andcare. This document and its contents, including the viewpoints, dates, and functional content expressed herein are believed to be accurate as of its date of public

and Kanban execution. (See figure 7.1) Manufacturing Execution System MES is an easy-to-use, online system for the plant floor that allows plant-based transactions real-time visibility throughout the Epicor solution. Epicor MES enables accurate labor reporting, as well as online transaction tracking, which provides management with a real-time .