Roadmap - Supply Chain Management (SCM) | Inventory Control Management

Roadmap – Supply Chain Management (SCM) Streamline your Supply Chain Management

www.roadmapit.com

Supply Chain Management 01 Inventory Control Agenda Contents 01 - Modules

Get a modern PowerPoint Presentation that is beautifully designed. I hope and I believe that this Template will your Time.

Style

02 Purchase Order

03 Sub Contracting 02 Contents

Get a modern PowerPoint Presentation that is beautifully designed. I hope and I believe that this Template will your Time.

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

5

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

6

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

7

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.

8

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.

21

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

9

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.

10

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

11

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.

12

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

13

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.

14

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

15

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.

16

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

17

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.

18

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

19

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.

20

MIS Dashboard

THANK YOU