Factory Control Systems

 

Specialist Furniture for Hospital, Laboratory and Schools

The Factory Control Systems software has been extensively developed for any business involved in the manufacture & distribution of batch or piece-part consumer goods incorporating easy to use 'windows point & click' applications for customer and purchase order processing plus superb operational controls designed to help in the management of the shop floor personnel and processes. Covering works orders and MRP facilities, Stock and inventory control, Capacity and distribution planning along with detailed costing and time & attendance, plus the associated reports and data for all your sales and factory performance monitoring.

We have a structured implementation program using our own staff who have worked directly in the furniture and allied industry and will be directly familiar and understand the issues and terminologies of the industry. This ensures our staff can easily understand the specific issues each customer is concerned about.

With experts in manufacturing, distribution CRM, Supply chain management and accounting you are assured of advice on best practice during implementation.

Features of Works Orders Processing

• The system has the facility to monitor production through both multiple, and limited numbers, of routes, operations and processes as required
• Facility to print Works Orders for each Work Centre name, or by individual Project No., according to how your business operates
• Screen automatically displays all open orders against each item, plus the quantity outstanding at each operation, for each order
• Optional 'Back-flush' feature automatically removes components from issuing Stock Room, when Works Order is booked as completed
• Daily recording sheet for each Work Centre / Operation which shows all requirements and what overdues are outstanding
• Facility to automatically 'multi-book' by Work Centre name, or to individually book a Works Order through keyboard or by barcode, with indefinite number of partial bookings allowed
• Full and comprehensive 'suite' of reports available to show all transactions for both Works and Purchase Orders, that allows the user to see how many are outstanding, and on what date the last issue or receipt took place, along with all 'usage' information, MRP requirements and stock levels

Features of MRP II

• Software has been developed for fast execution, rather than taking the 'traditional' hours for overnight runs
• Facility to run full MRP explosion for the full order book or an individual Project No., through every level of the Bill of Materials, checking stocks and outstanding Works Orders and Purchase Orders at each level in minutes
• Feature for automatic reallocation of stock in each stock area against current live orders
• Options to run MRP from either Customer Orders or from Works Orders, with a 'suite' of reports to show suggested Purchase and Works Order requirements by unique project No. / by date / by item, along with their stock records, and a 'button' for the subsequent auto-creation of the actual orders on the system, ready for confirming for print out and processing

Features of Stock inventory control

• Control movement between as many stockrooms or locations as your business requires
• Option to set purchased product by daily / weekly / monthly policy, for efficient purchasing and cash allocation
• Information on physical, allocated, quarantined and available stock routinely viewed on screen, or printed to hard copy
• Facility to provide information on usage on every item, along with ABC analysis
• Facility to record stock in multiple rack / bin locations for each stockroom
• Option to automatically control stock re-order points by using minimum and maximum stock level parameters
• Stock valuation report summarised at standard or current costs by stockroom, with an accompanying total for all stockrooms
• Stock reports by item code / description given by stockroom highlighting stock levels as low, high, or OK, according to minimum levels and resource requirements, along with the various 'flags' and usages set against the item
• Facility for taking on stock through Stock transfers, Stocktake adjustments, and Quarantine by just keying-in the quantity and clicking on the reason for entry, or by using the latest barcode technology for labeling and remote data capture units
• Stocktake sheets printed out by stockroom name, to help in identifying what and where the stock should be, and to provide an 'easy prompt' for an entry
• Facility for entering an EOQ (economic order quantity), to ensure internal and external orders are ordered in acceptable batch sizes
• Easy viewing in tabular form, of all product 'Options' that have been set up and validated as being acceptable to sell to customers, and that have also been evaluated through a Stock Master 'cost roll-up'
• Facility to 'auto-create' the Stock Room Master record without the need to individually set one up for each item
• Option to set 'buy to order' for back to back purchasing policies keeping any buffer emergency stock.

Features of Capacity Planning

• Diagrammatical presentation, by percentage and colour codes of over / under capacity against each Work Centre / Operation, by weekly or daily capacities, based on the cycle times for each item as entered in the Bill of Materials, and the capacities set up for each Work Centre record
• Flexibility to run MRP with or without affecting Capacity Planning
• Facility to temporarily change or amend the forward capacities on a daily / weekly basis from the ones already set up for each Work Centre, that will allow you to carry out as many 'what if' scenario's as you require, to help in balancing the operations and processes

Features of Distribution Planning

• Visual on screen display on a map of the UK, of where, and what your orders are, along with a 'zoom-in / zoom-out' facility that takes you right down to street level view
• Facility to set up and select multiple vehicle types, holding different cubic capacity volumes
• Visual on-screen display of vehicles volume capacity utilisation, as the orders are being planned
• Change of screen view to easily highlight overdue orders, returns and exchanges, and to exclude orders beyond any future due date
• Automated Postcode validation and Address matching features
• Allocates items to load / load number, and optimises for best drop sequence, and then routes by mileage / time for most efficient journey
• Facility to select and 'filter' orders, which enables exclusion, or inclusion, of only those orders or products that you wish to include in the plan
• Prints driver documentation and itinerary in drop sequence, along with all the customer delivery point information and product details that are required
• Can set up multiple delivery regions / areas by postcodes, to allow filtering of orders by area, or to view all orders on map
• Quick 'look-up' facility for locating a particular postcode, town or other place names
• Unlimited number of drops / calls can be entered within the route
• Facility to enter and use your own measured Standards for road speeds, and the other work associated with deliveries such as drops and unloading, and Focal Points for Draw Bar operations
• Can plan to cubic capacity or to weight or to quantity, according to how your business operates
• Easy selection of orders from on-screen map to each load, followed by fast execution of optimisation for best drop sequence, and the route calculation

Features of Costing:

• Effortless calculation of selling prices
• Can build up costs to any level of the Bill of Materials, and report on 'rolled-up' costs at each level
• Facility for auto-calculation of costs working up the Bills using current or standard costs
• Click on an item to pick up material and labour costs from the Bill of Materials, or enter an estimate and the system will automatically work out the portion of overhead to apply
• Reporting of costs at current or standard as required, with facility to transfer current to standard at any time, for budgeting and variance reporting purposes
• Global default Percentage figures for consumables, overheads, distribution costs and profit or specific item percentage values, can be set. The system will hold these percentages and re-calculate the values as costs fluctuate
• Versatile options on costs generated by the BOM allows the user to build in specific operational overheads, to recover costs of capital equipment e.g. CNC machines
• Enter a specific selling price, and the system will show the profit made at that price
• Option to work from a fixed selling price with set increments for specific options (automatically calculated as options selected) -Or cost plus margin (global or specific) to determine the selling price. These costing rules can be set at item level as appropriate
• Enter the profit, and the system calculates the selling price, ensuring overheads, as entered, are correctly covered
• Facility to enter default percentages for consumables, distribution, and overheads, which are applied if there are no other fixed values specifically entered against an item
• Simple entry and application of Standard Costs v Current Costs for easy viewing of variances

Features of Sales Orders Processing

• Multiple address facility for acknowledgement, invoice and delivery held for each customer
• Default addresses automatically selected and entered when an order / quotation is created
• Alternative addresses can be selected from the available addresses, specific to the customer, or if the address is a one off delivery address, it can be entered directly against the order as it is being entered
• Optional cross reference to customers' product descriptions, codes and prices can be held for each customer
• Ability to hold each customers' stock numbers and references (catalogue / brochure number), if different from the manufacturing part number / description
• Facility to hold multiple prices per item, with options for price breaks for different quantities, along with discounted prices for a date range, by product, by customer
• Facility to enter any combination of 'Options' of colour or size etc. against an item, that have been set up and validated in the Stock records, and which also show as a list of all possible 'Options' for that item on the order details screen for easy selection or amendement when entering the order
• Automatic 'prompts' and checks to prevent invalid orders being entered or released for manufacture
• Easy switch from 'quotation', to 'order' status, enabling the release of an order for manufacture to the next MRP 'explosion', and again an easy switch to 'completed' status once the order has been despatched
• Automatic Order Acknowledgement / Quotation report available in detail, or by summary, depending on the status of the order
• Facility to enter an instructional order for product returns, and setting the order to a 'returns' status, along with entering the appropriate reference data for easy tracking
• Ability to enter multiple reference numbers and data against each order - i.e. project / sales order / customer ref / sales ref / our ref / etc.

Features of Factory Performance Monitoring

• Full 'suite' of reports to check and monitor rejects, plus material and labour performance against standard at every stage and operation within the manufacturing and purchasing processes
• Operational and process reports can be developed to monitor 'key' elements of the business, which will run from the data collected from the bookings made throughout the system
• Accurate evaluation of internal and external suppliers for Quality and 'on-time' performances
• Stock transactions can be viewed for any date range, sorted by type of transaction - adjustment / despatch / stocktake / etc.

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