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Annexure
D |
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Module |
Subject |
Details |
Phase. |
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Advanced
= Engg, Purchase , Stores , QC, &
Production |
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Advanced
= Engineering |
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Masters |
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Bill of
Materials( RM + Components + Consumables). Concept of Revision no, BOM
Tree, Multiple use Materials, 3 dimensional BOM with Time/production Stage
referencing |
Two |
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Cost |
Material costing |
Product wise
BOM based Raw Material costing. - based on Recent Purchase Price, and
Standard BOM. Computation of Contribution %, Labour and Overheads costings
is excluded. |
Phase-2 |
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Advanced
= Stores |
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Store Indents (production /assembly ) |
Stores Issue Requests |
Issue of material acc to Production Requests. Issue of
material according to BOM. , |
Ph-2 |
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Job
Workers |
Advanced |
Jobworker
reconciliations, 1-to-1 correlated, Conversion of Form , Moulding
/Fabrication Vendors reconciliation. Job work account, Plant ledger, Loss
allowed %. |
Phase
-1 |
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Advanced
Purchase functions - part 2 |
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Purchase |
M.R.P. |
Material
Requirement Planning . Purchase Planning, based on stock positions, BOM ,
Production Plan, Sales plan and the minimum level buffer stocks , Std
Order Lot Qnty |
Three |
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Other
optional modules added |
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Projects |
Time and Action |
TNA - Time and
Action Reporting. What tasks given to whom and what is the current status
? Which activities are in time v/s. in Delay ( Yellow & Red Zone) --
Can also be used for any Shipment, any Sampling. Any project . Helps in
reducing Time Used. |
Three |
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Correspondense |
External |
Log of every
mail, contracts, fax, samples inwards, outwards , drawings sent and
received etc + Electronic Dak Register |
Phase-1 |
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Gate |
Basic |
Entry of
Material inward at the Gate itself,
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Phase-1 |
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Advanced
= Purchase Work |
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Purchase Indents |
On-line Indent |
on-line
Purchase indent , and see what is the status of my indent, and make it
100% compulsory (on-line) only |
Ph-2 |
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Purchase |
On-line |
On line
approvals of Purchase Indents - with no |
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Job work Request |
On-line |
on-line Job
work indent , for any "jobwork", - make it compulsory for any
Job work requirement - fix the price, fix the vendor,
fix which process ? Based on a Job Work Order |
Ph-2 |
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Service Request |
On-line |
on-line Service
indent , for any "service", and see what is the status of my
indent, and make it 100% compulsory (on-line) only . Here no Material is
involved, and no MRR shall come in. |
Ph-2 |
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Purchase |
Schedules |
Facility
of Open Purchase Orders +
Purchase Schedules - Daily, Weekly, Monthly, Yearly. Connected with
Stores inwards. Tracking of Schedule vs Despatch of vendors,
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Two |
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Advanced
= Stores |
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Store Indents (non-production ) |
On-line Indent |
The different
users whether at production, accounts, maintenance or EDP , make on-line
store indent , and see what is the status of their indents
( no paper slips required ) |
Ph-2 |
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Batch No. Control |
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Controlling the batch no system of
Materials and finished goods. With date of purchase/manufacture,
supervisor, Input details etc. Also facility to know , when this material
is going to Expire.( and should not be used ) Batch no concept, Issue of
material- MRR-wise. Facility to control source wise stocks. |
Ph-2 |
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Advanced
Purchase functions - part 2 |
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Purchase |
Vendor Ratings |
Vendor
Ratings-DPPM, QPPM, Price monitoring, Vendor wise price comparisons, item wise
comparisons, Rate Trends, ABC analysis |
Three |
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Purchase |
Imports |
Spl features for Import PO, multi currency, linked to
Stores and landed cost later. |
Phase
2 |
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Quality
Connected - Advanced |
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Quality-Inward |
Basic |
QC
colm in each MRR. No issue of material without QC, Updation of each MRR
with Pass-Fail-rework flag. Basic
inspection / failure reports |
Phase
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Quality |
Adv. Quality-Inward |
Material Receipt and Inspection Report ( MRIR) with
templates, Separate key parameters to check for each material, like
dimensions, weight etc. |
Two |
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Quality |
Quality-Out |
Standard & Customised PDIR for various customers, with
various parameters, So
that we can tell the ERP, which item is to be passed or failed on which
technical parameters, for general or that specific customer. Now the
reporting can be done. |
Two |
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Quality |
PPM Reports |
PPM Reports on the Quality Inwards and Quality Outwards.
--> To monitor the rejection ( Part per million) on the Factory final
inspection stage. A rejected batch may effect the overall QC rating of the
plant. |
Three |
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Quality |
HOLD |
Facility to Hold a Material Shipment during inspection. (
ex. For Further tests, for approval by customer, for approval by 3rd
Party, etc. ) This can give additional Reports of why put on hold, This
also saves the QC dept of the answerability on the shipments which they do
not pass, and where some outside body is involved |
Three |
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Quality |
Reports |
Special purpose Inspection Reports, with inspector Name,
Date, Time, lot, Qnty as per challan / actual / passed / failed
and also passed under deviation or
segregation, if any |
Three |
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Quality |
Reports |
Search facility in Inspection Reports |
Three |
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Quality |
Reports |
Quality Rating of Vendors, with factors like Line Rejection
due to Vendor, and Customer Rejection due to Vendor, Wrong labels,
Documentation problems, poor packing, Communication points and so on. |
Three |
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Quality |
Reports |
Facility to Record when each MRR(SRV) is received by
Inspection, alloted to which inspector, when alloted, when inspection
done(auto-filled), how much time delay , reason for delays.
+ with Google type Search reports on these. |
Three |
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Quality |
Reports |
In-process QC, with QC dept monitoring the flow of goods
from one process to another, the rejections at each stage, rework at each
stage, and other in-process reasonwise rejection analysis.
With appropriate slots in the production batch cards. |
Three |
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Quality |
Cost of Wastage Reporting |
Stage wise, shift wise, item wise batch rejections
+ What is the cost of wastage, what money the company is directly
losing due to the wastage/rejections. |
Three |
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Quality |
Engineering Change / Recipe Change |
As soon as this change is “logged” in the ERP. The ERP
will generate an AUTOMATIC “
ERP-message” to the users of Purchase, Quality and Stores, that this
change has happened. --- So
that effective that date, the people do not use the wrong version / recipe
/ BOM |
Three |
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Quality |
Urgent Inspection Request |
Suppose, last month 20 shipments were "critical"
and "urgent due to material shortage" etc, and due to this
urgency QC Team had to inspect them same day. This is ok, but this leads
to delay in the inspection of the non-urgent shipments. |
Three |
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Quality |
Urgent Inspection Request |
So, QC dept can generate a database of such
"emergencies" so tell who has these problems. This flag is
“set” at SRV stage itself. (a)
Generates on-line Alert to the QC Dept users, (b)
Report of “urgencies” and their disposal. |
Three |
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Quality |
Vendor Approval |
For approval of any New Vendor / any vendor for any new
item, some 14 steps must be passed from QC angle. Example, ISO certificate
copy taken ? Factory visit done ? Quality plan received ? |
Three |
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Quality |
PPAP |
Internal Audit Schedule , Plan for System, Process and
Products (data for the same is to be entered Once in a year)
+ Monitor whether the QC dept is doing as per schedule ? |
Three |
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Quality |
Tools |
Detail of Instruments and Gauges with Least count,
Calibration Frequency, location and calibration agency ==> Master List
, calibration Plan and history card for Instruments and Gauges
with reminder Facilities |
Three |
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Quality |
Tools |
Plan of MSA with reminder Facilities, with filtration of
Products, Customer and months. |
Three |
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Quality |
Tools |
Plan of performance Tests with reminder Facilities with
filtration of Products, Customer and months |
Three |
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Quality |
Customer Complaints |
Customer Complaint Log Book with Filtration of Products,
Customer and defects. Also having the information of Open and Close till
date |
Three |
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Quality |
Customer Complaints |
Customer NCR Monitoring with filtration facility along with
open and close status till date. |
Three |
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Quality |
Customer Complaints |
PDI Register with reason of rejection Item SKU wise,
customer wise and reason for rejection |
Three |
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Quality |
Customer Complaints |
Summary of material dispatch under deviation , Month wise,
customer wise and item wise. |
Three |
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Quality |
Customer Complaints |
Summary of stop shipment due to customer complaint |
Three |
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Ideal Benefits
to the client |
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1.No
Need of Making many of the MIS Reports on Daily Basis in Excel. |
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2.No.
Need of Calculate Supplier Rating in Excel |
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3.No
Need of Making MIS of process in Excel. |
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4.Accessible
to All Concerned of Engineering
Change Record |
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5.No
Need of Making Schedule of Instrument calibration, Performance test, and
MSA Plan Monthly. |
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6. No
need of Making Internal audit schedules for products, process and system
month wise |
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7.Data
is available on the system to all to see the latest revision of documents,
Drawings and BOM’s |
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8.Alteration
is not possible in data without prior approval of senior management. |
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9.Better
monitoring of Customer related issues such as returns and complaints. |
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10.Accuracy
and Time Saving |
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11.Accessible
all data to senior management . |
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12.Transparency
and better communication between various plants |
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