Roadmap – Supply Chain Management (SCM) Streamline your Supply Chain Management
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Supply Chain Management 01 Inventory Control Agenda Contents 01 - Modules
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02 Purchase Order
03 Sub Contracting 02 Contents
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04 Gate Entry Management
03
05 Transportation Contents Get a modern PowerPoint Presentation that is beautifully designed. I hope and I believe that this Template will your Time.
06 Sales Order
04
07 Quality Management Contents Get a modern PowerPoint Presentation that is beautifully designed. I hope and I believe that this Template will your Time.
Roadmap Milestone Company Started & ERP Development commenced
ERP Feasibility Study
2001
2009 Reached 30 Customers Company’s Employee 140
Successful Implementation done @ 1st Customer place Company’s Employee 70
2003
2012 Reached 80 Customers Company’s Employee 170
2006
2015
2020
Reached 350+ Customers Company’s Employee 400+
Reached 140 Customers Company’s Employee 210
3
Scalability
ERP Corporate
Legal Entity 1
Legal Entity 2
Unit 1(Manufacturing)
Warehouse
W2
Unit 2 (Distribution)
Sales
Unit n (Manufacturing /Distribution)
Work Center/Process/ Production Line
Procurement/Finance/Sales
Purchase
Legal Entity n
Finance
Work Center 1
Work Center 2
Work Center n 4
Web Enabled
Internet / VPN / RF / Lease line
Mobile Apps •CRM (Marketing, Field Service) •Employee Self Service •Approvals & Notification
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Supply Chain Management Be equipped with real-time Business Intelligence, and reduce operating cost and time between cash-to-cash cycles; by efficiently scheduling procurement, manufacturing, and transportation.
Workflow Approvals
Inventory Tracking
QR Code
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Inventory Control – Process Flow Prepares production plan & crushing plan Planning Purchase Request
Generate Purchase Order
Purchase
Supplier
Gate
Receives Purchase Order
Enter material inward details Enter Accepted/ Rejected, QI details
Quality Control
Convert the Gate Entry into GRN & forward it to QC for Quality Inspection
Stores/ FG WH
Shop Floor
Sends material along with DC & Invoice
Stock Count enters
Receive QC completed Material
Compare System Vs Physical
Receives approved material request & Issue Material Update Stock
Inventory Plan ROL / Min-Max Planning SFG/ FG Receipt
Raises material request for production order
Receive the material
SFG/ FG Completion
Material Return
Material Request for the SO
Receive the material
SFG Assembly FG Completion
Material Return
Material Request
Receive the material
Material Request against WO
Receive the material
Subcontractor
Material Receipts
Material Return
Department
Maintenance
Material Return
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Inventory Control – Features Definition of multiple item types, classes, subclasses, groups, subgroups and assign the items. Multiple UOM and conversion factors at item and UOM level. Active, inactive and obsolete statuses for the items. Define multiple type of warehouses (1) Standard (2) Rejection (3) Excess (4) Subcontractor (5) Customer (6) Rework etc.
Benefits Tracking pending material requests . Efficient inventory planning and control (1) Reorder level Planning (2) Min / Max Planning (3) MRP Planning.
System generated Purchase Request / Production Order/ Material.
Tracking different type of items stock such as (1) Raw material (2) Consumable (3) Packing Material (4) Semi-finished goods (5) Finished goods (6) Spare parts (7) Assembly etc at inspection warehouse, Rejection warehouse, WIP, FG, Subcontractor etc.
Request automatically when stock reaches Re-order level/ Minimum level.
Tracking rejected and scrap materials.
User access level warehouse-wise item / sub-class / class for purchase / material request.
Material Consumption Analysis – Department-wise, class-wise.
Material consumption - approval & budget control.
Periodical Stock on hand Analysis (Qty & Value ) –WH-wise, class-wise.
Material Request (1) WIP(Production Order) (2) Subcontractor (Subcontract order) (3) Department (4) Warehouse and approval.
ABC analysis based on individual item value/ consumption value.
System generated MIV for available stock against the Material Requests and MIV Posting.
Physical Stock Count – Stock Shortage / Overage Analysis.
Supports to maintain bins in the warehouses.
Material Return (1) WIP (Production Order) (2) Subcontractor (Subcontract order) (3) Department (4) Warehouse and approval.
Current stock Analysis (Qty & Value) – WH-wise, class-wise.
Fast Slow Non (FSN) moving item analysis. Tracking expired items (lot number and qty).
Inventory costing methods (1)Weighted Average Cost (2) LIFO (3) FIFO. Stock count comparison during different period / year without freezing the warehouse operation. Material transactions controlled by material management.
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Inventory Control Real Time Tracking Effective Real time tracking of inventory levels even between multiple warehouses geographically separated.
Cost Management Manage costs of goods sold and inventory holding costs, through automatically generated GL entries.
Item Code Track and control the Levels of Stock through the provision of Lot and Serial number to individual products.
Maintenance Of Stock Efficient maintenance of stock batches through KANBAN Inventory Control; ABC analysis; and FSN analysis.
Automatic Replenishing The module's integration with the manufacturing process facilitates the automated generation of POs to refill and keep the Inventory well stocked.
Time Efficiency Efficiently handle your planned Order Release quantity by being able to issue materials of all sorts from your inventory on a single click of a mouse.
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Purchase Order – Process Flow Planning Department
Plans the Raw Material & Packing mat. Requirement and Prepare Purchase Request Supplier Sch.
Receive Approved Purchase / Supplier Schedule Request
Pur./ Sup. Schedule
Prepares and sends quote against RFQ
Receives Purchase Order / Supplier Schedule
Supplier
Automatic creation of purchase request based on the Reorder / Min / Max planning
Creates GRN manually or convert the Gate entry into GRN & sends to QC for QI
Accounts Payable
Receives quote, enter details and prepare comparison chart
Registers the bill against GRN
Allow the vehicle and enter the Material Inward, DC & Invoice details
If the First Stage inspection
Supplier receives rejected material
Forwards the invoice to Finance Department
Return the goods
No
Yes
Receive the first stage of inspection request and sends the test result
Supplier sends material along with DC & Invoice
Receives the Accepted / Rejected material
Yes
No
First Stage of inspection required
Quality Control
Generate RFQ and send it to Supplier
RFQ
Receives RFQ
Gate Entry
Place Purchase Order / Supplier Schedule
Purchase
Purchase Department
Stores
PO
RFQ/ PO
Receives the material along with Inspection Request
Inspects the materials enter observation, accepted & rejected qty
Prepares Debt Memo / Invoice and return the rejected / excess material along with Invoice / Debit Memo
Forwards accepted / rejected material to stores
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Purchase Order – Features Approved suppliers for the items, share of business, contract prices/ catalog prices / standard / user defined prices . Purchase request for stocked / non-stocked with detailed schedule of qty and date with/ without RFQ. Purchase Request – Cancellation / Close Short. Supplier Schedule Request and Approval. PR / PO approval authorization and budget validation. Single/multiple RFQ generation from single / multiple purchase requests. Supplier quote price entry and price comparison.
Benefits Tracking Purchase Request / RFQ / Quotation / Order/ Planned Material receipts at any instances.
Tracking Pending Purchase Request ( Order Conversion). Tracking Pending Purchase Order by Supplier / Buyer / Item. Summary and Comparison of purchases yearly/ periodically. Comparison for budgeted vs actual purchases. Supplier Performance Rating.
Conversion of single quotation to single / multiple PO's.
Tracking pending purchase request / purchase orders / short close purchase orders.
Conversion of single / multiple purchase requests to single / multiple PO's.
Amended purchase order excess quantity / pre-printed format.
Conversion of Supplier Schedule Request into Supplier Schedule Order.
Periodic purchase receipt / price comparison / purchase summary.
Supplier's credit limit alert. PO amendments, PO cancel / close short. Supports PO to receipt qty tolerance%, early / late day's tolerance and partial shipment allowed option. Conversion of Gate Entry into Goods Receipt Note. Multiple GRN for single PO / supplier schedule order and single GRN for multiple PO's/supplier schedule order. Handling excess quantity and waived quantity receipts. Register landed cost and apportion it to single / multiple GRN based on value / weight. Rework and accept the purchase rejection. Single / multiple purchase return for single / multiple GRN rejected quantity. Raising Debit note / invoice for the purchase rejection. return / excess quantity receipt return w/wo GRN reference and w/wo goods / QPD variance.
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Sub Contracting – Process Flow Prepares RFQ for item process and forward to sub contractor
Receives quote prepare open PO/ Amendment
List of pending outside processes
Convert into sub contractor order & approves
Sub Contracting Department
Subcontractor
Planning Department
Receives RFQ for Item processes and prepares quotation & forward to the organization
Receives open PO/ Amendment
Process the Material and sends along with DC & Invoice
Receives Debit Memo for the Primary/ Secondary rejection item
Prepares production order and copies the processes from product routing
Material request & allocation
Material Issuance to subcontractor with DC
Stores
Gate Entry
Receives sub contractor order along with material & DC
Convert the gate entry into GRN, generates material consumption against DC & forward to QC Department
Stores department receives the material, stock decreased at subcontractor location
Forward the GRN details along with bill to finance department
Enter the material inward details in 7 categories 1. Processed 5.End Bits 2. Unprocessed 6. Cut Samples 3. Declared scrap 7. Partially Processed 4. Scrap
Inspects the material enter the QI observation, accepted & rejected details and sends back to the store Quality Control
Register the bill against GRN
Prepare Debt Memo / Invoice and return the Primary /Secondary rejection item W / WO material
Accounts Payable
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Sub Contracting – Features Subcontract Labor contract rates for each supplier, item & process.
Benefits
Subcontract requests with the required BOM Specification.
Tracking expired Open PO for the item process purchases.
Conversion of subcontract request into subcontract order with BOM Specification, which facilities expanding or decreasing the sub-contracting process.
Tracking unprocessed subcontract requests, supplier schedule requests.
Creation of Subcontract orders from Production shop floor process pending buckets.
Tracking un-received subcontract order / suppliers schedules etc.
Subcontract order for Rework, Value addition etc.
Tracking pending gate entries for GRN conversions.
Auto creation of material requests, material issuance and DC for subcontract orders.
Tracking pending GRN lines for quality inspection.
Subcontract Order Close short / Amendment. Entering Landed Cost and apportioning to single / multiple GRN's. Subcontract GRN for (1) Processed (2) Unprocessed (SFG) (3) Supplier Declared Scrap (4) Scrap (4) End bits (5) Unprocessed (Std) (6) Cut Samples (7) Partially Completed. Subcontract receipts through Gate Entry option. System generated material consumption as per BOM and adjusting against the DC's.
Tracking quality completed pending GRN lines. Subcontract Analysis : Yearly / Periodical Class wise / Supplier wise / Buyer wise / Process wise. Subcontractor Performance rating. Tracking stock at subcontractors at any instance. Tracking pending DC with subcontractors. Tracking pending subcontract orders, requests etc.
Raising Rework order to repair/ disassemble / scrap the primary / secondary rejected items. Raising debit memo for the Primary & Secondary rejection W/WO material.
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Gate Entry Management – Process Flow Sends PO for the Material Purchase Department
Supplier
Receives PO & Sends the Material
Receive the material along with DC
After Processing sends material along with DC & also returnable DC Material
Sub Contractor
Receive the material along with DC
Sends the Sales Return material
Receives the Machine/ Tool for external service
After completion of the process sends the material along with DC
Prepares Sales Invoice
Creates delivery challan for the returnable / nonreturnable materials
Customer
Service Provider
Commercial Department
Subcontracting Department
Maintenance Department
Transportation
Gate Keeper
Sends Subcontract Order
Creates delivery challan for the returnable / non returnable materials
Prepares DC for the Machine /Tools which requires external maintenance service
Prepares Trip Sheet with DC &Vehicle details
Register the following inward details: 1. Purchase Material 2. External Service Machine / Tools 3. Sales Return 4. Others
Post the Document
Register visitor In & Out details, Register vehicle Out details
Register Outward details
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Gate Entry Management – Features Register all Returnable and Non Returnable inward details such as (1) Vehicle details (2) Material details. Option to capture the gross weight of incoming vehicle, tare weight while vehicle going out and determine net weight of the goods. System / manual created returnable / non-returnable DC's from various sources Consolidate the DC's created from multiple source and generate single / multiple outward entry with vehicle details. Track the returnable material with aged days. Visitors Gate Pass. DC to DC matching / mapping.
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Transportation – Process Flow Sends quote for transportation price
Carrier sends bill for the transportation services
Register the own Vehicles available for transportation
Request quote for the rates different destination, shipment mode, weights etc.
Carriers
Transportation Department
Commercial Department
Purchase Department
Prepares transportation schedule with different carriers/ company own vehicle
Fixes the prices in the masters for various carriers
Prepare Trip sheet with different pick from / ship to Location
Register the sales orders with ship to location and required date details
Register the purchase order with different pick from location and the required date
Register the bill for the transportation Accounts Payable Department
Makes the payment against the bills Cash Management Payable
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Transportation – Features Define organization own vehicle details. Define different carriers, rates for different transport modes such as Road, Ship, Air, based on the weight, distance etc. Efficient Transportation Schedule preparation for the material inward / outward (1) Purchase (2) Subcontract (3) Material Transfer (4) Sales Invoice
(5) Others etc. with company. Trip sheet Preparation with pick and drop details and associating DC's with it. Register invoices for the transporters from the trip sheets. Comparison of actual freight collected from customers and paid to the carriers. Payment to the transporters.
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Sales Order – Process Flow Customer places Purchase Order
Customer receives material, invoice& DC
Customer returns rejected material
Customer makes the Payment
Customer receives the Payment Receipt
Customer
Commercial Department
Books the sales order or converts from sales quotation into sales order / register customer schedule
Prepares Packing list and Invoice
Register Sales Return
Prepares production plan & crushing plan Planning Department
Produces FG as per planning requirement Shop Floor
Accounts Receivable
Receives Invoice
Cash Management
Prepares Bank / Cash receipt voucher
Register DN / Invoice Received
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Sales Order – Features Multiple pricing – contract / catalog /standard /user defined prices for different periods.
Benefits
Sales order for multiple items with different delivery schedule and Bill To / Ship To addresses.
Track Open SO / Sales Order Amendment History.
Sales order validation for the customer lead time, available to promise and promise date determination. Supports multiple sales unit of measures. Firm control over credit limit. Sales Order approval / Close short / Cancel. Complete sales order picking / partial picking, multiple shipments to single / multiple invoice. Generating Pro-forma Invoice for (1) Advance (2) Pre-Dispatch Receipt and amount receipt against proforma invoice. Supporting 14 types of sales Invoices (1) Standard (2) Stock Transfer (3) Stock Transfer 3PL (4) Supplementary (5) Scrap (6)Labor (7)Service (8)Input Sales (9)Project Invoicing (10) Demo/ Exhibition (11) Fixed Assets (12) Free Replacement (13) Free Sample (14) Transfer Service Tax. System calculated tax & charges and different running invoice numbers.
Tracking expired / about to expire open SO items. Tracking pending customer sch. / Sales Orders / Labor Orders. Tracking different type of invoices (1) Domestic (2) Export (3) Stock perfect calculation of taxes and charges. Easy generation of Sales Registers (1) Invoice-wise (2) Item-wise. System generated Proforma invoice / picking list / packing slip / delivery challan. Track the delivery schedule and follow-up production. Sales Analysis : Yearly / Periodical / Group-wise / Subgroup- wise / Customer-wise / item-wise. Sales Return Analysis : Yearly / Periodical / Group-wise / Subgroupwise / Customer-wise / item-wise. Profitability Analysis : Yearly / Periodical / Group-wise / Subgroup- wise / Customer-wise / item-wise. Dispatch : Early / On-time / Late delivery analysis.
Sales Return (1) Return W/G (2) Return WO/G (3) Labor (4) Service (5) Supplementary (6) Others (7) Stock Transfer (8) Demo / Exhibition (9) Replacement (10) Sample. Single/Multiple commercial invoice to Single/Multiple excise invoice.
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Quality Control Management – Process Flow Stores Department
Purchase, GRN- Inspection Request WIP Return, Predispatch Inspection Request
Accepted/ Rejected Details
Production process completion, Final product Inspection Request
Accepted/ Rejected Details
Sales Return Inspection Request
Accepted/ Rejected Details
Sends first stage Inspection request
Receives the first stage inspection result and accepts / rejects the goods
Shop Floor
Commercial
Gate Entry
Quality Department
Receives first stage inspection request and sends the result
Create Inspection document, enter quality observation, defect details, accepted, rejected details
Complete the inspection doc. forwards back the material & QC report to originator
Receives Inspection Request
Shop Floor in process Inspection
Enter quality observation details
Open NCR & enter non compliance details and preventive action can be taken
Gauges entry, calibration due details
Enter action taken details
Is calibration due?
Quality Analysis 1. PPM Analysis 2. Defect Analyis 3. SPC 4. Pareto Analysis 5. Process Capability Analysis
Close NCR
Enter calibration Details
Update next calibration due date
MSA Register Study details for the Gauges
If Study Due
Create Study Record & update details
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Quality Control – Features Easy setup of Inspection plans for the Purchase items & manufactured items.
Calibration
Standard QC characteristics for the variables and spec for the Attribute types.
Gauges.
Single, double and multiple sampling.
Calibration Dues.
First Stage Inspection.
Calibration.
Collect and analyze the quality data's at the following inspection points.
Measurement System Analysis
(1) Purchase GRN (2) Subcontract GRN (3) Shop Floor transfer (4) Stock Inspection (5) Sales Return (6) Material Return from WIP (7) Material Transfer (8) Service Work Order.
Bias Study.
Shop Floor - In Process Inspection. Inspection Document (1) Register value for Variable & Visual characteristics (2) Enter defect codes and quantity (3) Register Accepted, Accepted On Deviation(AOD), Primary & Secondary Rejection quantities (4) Register defect code and quantity.
Linearity Study. Stability Study. R & R Study.
Benefits Tracking pending inspection requests (1)Purchase (2)Subcontract (3) Shop Floor (4) Sales Return.
Serial number tracking for the defects.
Non-Conformance/ Monthly Inspection Status.
Raising NCR for the Purchase / Subcontract/Shop Floor / Sales Return Rejections
Efficient Defect analysis (tracking the defective products by defect code and reasons).
Parts Per Million (PPM) Analysis.
Pareto analysis on attribute data & quality related variable charts.
Statistical Process Control
System generated quality related variable charts.
Process Capability Study.
Tracking QC history data.
Process Performance Study.
Tracking Open NCR items.
Pareto Analysis.
Tracking calibration gauge due & MSA study due records.
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