Business Needs

	Control Product Design Changes
	Ensure Quality of Raw Materials and Monitoring During Production Process
	Manage Complex Production Recipes
	Manage Different Units of Measure for Different Levels in Product Bill of Materials
	Manage Product and Raw Material Traceability
	Reduce Costs and Eliminate Waste While Remaining Flexible and Responsive

Key Features and Functions

	Advanced trial kitting	Co-products
	Available-to-promise	Distribution requirements planning
	Backflushing	Kit issues
	Bill of materials	Load planning
	Blanket purchase orders	Serial tracking
	By-products	Setup / Teardown
	Component fixed quantity per	Where used

Control Product Design Changes

Constant innovation is one of the key factors to remaining competitive and on-going research and development to design new and better products is integral to the industry. Your ability to design new products and modify existing designs, as well as improve time-to-market is critical to remaining competitive and profitable.

SYSPRO provides tools to streamline and track the introduction of new product designs and amendments to existing designs, along with relevant costings. SYSPRO's Engineering Change Control (ECC) enables you to apply strict control over your design-to-market processes by providing an integrated rules-based electronic workflow system with full version control, security and auditable history.

ECC gives you the tools to record and track new and modified product design and process changes, assess the impact of these changes on costs and associated data, and control the change routing and approval processes. ECC's queries, audit trail, history and archive facilities, give you quick on-line access to details of prior product versions, as well as the option of reverting to the production of a prior product version if required. In addition, the facility to attach copies of product design drawings to version and release levels provides access to visual details of revisions.

The Where-used Query facility enables you to identify all items affected by the raising of an Engineering Change order for all routes identified as being under Engineering Change Control. In addition, SYSPRO provides a 'replace component where-used' facility that enables the quick replacement of one item with a valid substitute item, thereby streamlining design changes.

SYSPRO's ECC, Bill of Materials, Work-in-Progress and Factory Documentation modules enable you to implement controls to ensure that your products are manufactured under consistent processes, to the correct designs and specifications. Single-level, multi-level, co and by-product bills are all catered for and flexible bill definitions accommodate complex component and sub-assembly requirements.

Ensure Quality of Raw Materials and Monitoring During the Production Process

Chemical production plants are often highly automated with sophisticated measuring and testing systems designed to ensure quality of raw materials and work in progress, as well as high production yields. It is therefore desirable that any ERP production control and tracking system is able to integrate seamlessly with this process technology to exchange information and highlight issues at the relevant points. SYSPRO e.net solutions enables rapid development of secure and version-independent integration with such best-of-breed technology.

SYSPRO enables you to implement continuous improvement by helping you to identify problems and points of waste as they happen. Raw materials and manufactured products in the industry often vary in grade and quality, so tracking and control is essential to reduce waste, scrap and defects. SYSPRO enables you to specify approved manufacturers for raw material supplies and supplier performance can easily be tracked using queries and reports. In addition, SYSPRO facilitates the tracking of materials from purchase through production to customer, thereby maximizing quality control and providing you with the tools to manage product recalls, should they occur.

You can flag purchased items as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns is recorded. Units in inspection are visible, but unavailable for use until accepted into stock. Similarly, SYSPRO's Work in Progress inspection system provides the tools for you to inspect manufactured product quality and, depending on the results, select to receipt, scrap or rework quantities.

Manage Complex Production Recipes

SYSPRO's multi-level bill of materials functionality enables the definition of complex production recipes of up to 15 levels per route, and 10 routes per finished product. Control over recipe changes is seamlessly handled by the Engineering Change Control module, while a where-used query and substitution facility enables quick and easy replacement of ingredients. SYSPRO's powerful costing and what-if costing calculations, reports and queries provide a comprehensive and accurate picture of purchasing and production costs.

The work center and structures and routings facilities provide you with the means to define and maintain the elements required in a sequence of internal or subcontract manufacturing operations, as well as the structural relationships between parent and component parts. Phantom bills are catered for to accommodate transient production items, and planning bill functionality aids option forecasting and planning. In addition, the configuration and manufacture of multiple items which are produced in a single process are catered for by SYSPRO's co- and by-product features.

For each bill level, you can define ingredient quantities such as quantity per, fixed quantities or wet weight percentages in relation to that specific level's parent item. Component and operation copy, insertion, and move facilities enable straightforward maintenance of new and existing bills.

SYSPRO provides various operation run time methods, as well as material and progressive scrap functionality. The capture of various lead time elements enables accurate calculations of manufacturing and cumulative lead times, which in turn aid efficient materials planning and production scheduling, as well as product costing.

You can simulate the effects of varying batches sizes and subcontracting on product costs and lead times. You can also add information on tooling, operator skill levels, operation instructions and testing requirements to the operation and print these fields on SYSPRO's user-defined factory documentation.

The relationship validation function enables you to easily identify illogical relationships within your bills, while the structure validation function facilitates quick deletion of redundant or superseded components from bill of material structures.

The Work in Progress module enables seamless ingredient substitution where actual ingredients differ from planned. Furthermore, where intermediate or finished products differ from planned, the Work in Progress inspection functionality enables receipting of these products as alternate stock codes, or into alternate warehouses or bins.

SYSPRO's multimedia functionality enables you to attach visual and textual material, such as videos, photographs, and certificates of conformance, to structures and operations, to aid production and quality assurance staff, while custom forms enables you to create additional user-defined fields.

Manage Different Units of Measure For Different Levels in Product Bill of Materials

SYSPRO's Inventory module enables the definition of multiple user-defined units of measure (UOM) for stocked items: Stocking UOM, Alternate UOM and Other UOM. In addition, a separate manufacturing UOM will be available in version SP3. These units of measure, along with their conversion factors are used in various parts of the system to ensure accurate quantities for sales, purchasing and production.

For production purposes, SYSPRO's multi-level bill of materials functionality enables you to define the manufacturing recipes and methods for bulk, intermediary and pack items, allowing for up to 15 levels per route, and 10 routes per finished product. For each level in a multi-level bill, you can define ingredient quantities as quantity per, fixed quantities or wet weight percentages in relation to that level's parent item.

Manage Product and Raw Material Traceability

Whether a compliance-critical requirement, or an analysis tool for continuous improvement strategies, the traceability of products from material origins through manufacture to final destination, is a key system requirement in many industries.

SYSPRO facilitates the recording of traceability and quality data on materials and products from purchasing through inspection, manufacturing, manufacturing inspection, stocking and sales. The recording of expiry and shelf-life information is also facilitated and powerful queries enable both upward and downward searches by stock code, lot number and transaction type.

SYSPRO's lot traceability and serial tracking functionality afford full visibility to the origins, build and customer destination of products and batches, thereby providing the means to easily trace and analyse the source of defects, should they occur. In addition, SYSPRO's Engineering Change Control module enables complete management and traceability of changes to product designs, while the Return Merchandise Authority module provide consistent handling of product returns, as well as analysis data for improvement programs.

Reduce Cost and Eliminate Waste While Remaining Flexible and Responsive

Understanding the true cost per transaction of doing business means identifying contributing elements, direct and indirect, across the entire organization. These include not only the cost efficiency of operational activities and their interrelationships, but also the time spent on manual and redundant processes, reconciliations, paperwork and reporting, as well as the cost of lost opportunities from a lack of agility in responding to the global marketplace.

SYSPRO provides essential integrated visibility to your accounting, distribution and manufacturing operations, thereby enabling you to easily identify and track your cost elements and to target areas of waste for improvement programs. Additionally, it facilitates the automation of many processes that have traditionally been labor-intensive and time-consuming, such as operational-to-financial reconciliations and communicating with trading partners.

It offers Standard, Average, Last, FIFO and LIFO costing methods flagged at warehouse level, thereby providing accurate operations-focused inventory valuation, which in turn supplies accurate input for product pricing and profitability. Comprehensive multi-level costing of manufactured items is provided through SYSPRO Bill of Materials and Work in Progress, with SYSPRO Product Configurator and Quotations and Estimating providing additional tools for assemble/make/engineer-to-order environments. Lot traceability, serial tracking and return merchandise functionality, along with SYSPRO's inspection systems, provide tracking of product defects, thereby helping you mitigate costly recalls.

SYSPRO's cost roll up and implosion functionality, along with user-friendly costing queries, provides fast access to reliable information on which to base pricing and profit margins. In addition, its extensive what-if costing features enables modeling and comparison of the cost effects of alternative inputs, such as raw materials, production routes, labor rates and subcontractor rates.

SYSPRO provides work in progress tracking, enabling evaluation of detailed actual versus expected costs, as well as targets for cost savings and continuous improvement programs. Used in conjunction with SYSPRO Projects and Contracts, it facilitates comprehensive project job costing. Visibility to production scheduling, along with what-if sequencing and scheduling tools, enhance manufacturing agility and competitiveness and help to prevent lost sales in unpredictable demand environments.

Excess inventories tie up valuable resources both in terms of cost and warehouse management. SYSPRO helps you optimize, manage and track your inventories through its multi-warehouse Inventory, Material Requirements Planning, Purchase Order and Work in Progress. In addition, the Purchase Order and Landed Cost Tracking systems provide a more accurate estimate of the full landed cost of imported goods, with the GRN matching and reconciliation features facilitating electronic reconciliation of supplier deliveries and charges.

Accounts Receivable, Accounts Payable and Cash Book provide comprehensive balancing and reconciliation tools, as well as credit and cash flow management capability. Additionally, efficient administration of customer accruals, rebates and deductions is facilitated through SYSPRO Trade Promotions Management. Commitment accounting is provided through SYSPRO Accounts Payable and Purchasing, while the Assets Register ensures accurate maintenance and depreciation costing, and asset profit and loss realization.

SYSPRO's General Ledger (G/L) provides powerful queries with drill-down from journal to transaction source, as well as at-a-glance financial and activity ratios. Processing time is greatly reduced through features, such as sub-ledger integration and reconciliation, journal copy, journal import, automatic weighted transfer of costs and G/L analysis. Furthermore, SYSPRO's ease of ledger consolidation across complex businesses, along with its XML-based financial reporting features, enables prompt web-based deployment of financial reports to SYSPRO and non-SYSPRO users alike.

SYSPRO's flexible user-defined stationery formats, along with SYSPRO Reporting Services (SRS), precludes the need for pre-printed stationery for invoices, delivery notes, order acknowledgments, dispatch notes, purchase orders and statements. In addition, SRS provides considerable savings by reducing the need for paper-based audit trails and reporting. Its automatic scheduling tool precludes the need for resource-intensive supervision of periodic and month-end reporting. Furthermore, the archiving feature provides for the electronic storage of reports as run, thereby enabling users to view them on-line to discern actual print requirements.

SYSPRO's Office (SOI), fax and email integration saves time, postage and paper by enabling you to deliver transactional documents, such as purchase orders and statements, directly from their point of extraction via secure electronic means. Additionally, SOI facilitates direct queries of key operational data from the desktops of enterprise-wide users and trading partners, without the need for the desktop installation or licensing of SYSPRO.

The capability to extend electronic communication, so as to automate the acceptance and acknowledgment of orders on a 24/7 basis, is provided via SYSPRO e.net solutions, Document Flow Manager and Web Applications. Furthermore, SYSPRO e.net solutions tools afford non-proprietary and version-independent integration to mobile devices and best-of-breed applications, such as shop floor control and quality monitoring systems.

The ROI of implementing SYSPRO is rapidly realized through full visibility to an integrated picture of your business operations and the resultant reduction in operational costs, processing time and human resources.

Advanced Trial Kitting

Advanced trial kitting provides you with a simple method of calculating date-driven material requirements when a full material requirements planning run is not needed. You use it to determine date-specific material requirements for which supplies must be raised, in order to satisfy date-driven demand for a range of manufactured products from various demand sources. A simple review of the calculated results enables seamless creation of supply orders, whether they be works orders, purchase orders or warehouse transfers.

Available-To-Promise

SYSPRO's available-to-promise (ATP) feature helps make reliable delivery promises to your customers, by showing you that portion of your inventory and planned production that is available to fill their orders and on which dates. You can choose between regular (discrete) and cumulative modes of display and can define which components of supply and demand should be included in the calculation.

Backflushing

Within, SYSPRO, backflushing enables you to record the manufacture of items without having to create works orders. This is particularly relevant in situations where the production runs are short and the benefits derived from creating a works order to track the activity on the shop floor do not justify the cost of processing all the data normally required for a works order. Backflushing enables you to receipt a finished product into stock and simultaneously post the relevant labor transactions and deplete inventory of production materials based on the bill of materials of the finished product. The system uses the manufactured item's bill of materials to determine the material and labor charges to be included.

Bill of Materials

In SYSPRO, a bill of material comprises up to 15 levels of components and quantities together with the associated sequence of operations needed to make one production run of a product. It provides detailed costing at each level in the bill and facilitates an accurate expected cost against which to track actual production costs.

Blanket Purchase Orders

In SYSPRO, blanket purchase orders allow you to create, maintain and use contract purchase orders as well as monitor purchase order receipts against a supplier's contract.

The purpose of these contracts is to allow a fixed price to be recorded for a specified period and/or volume, plus an agreed delivery schedule. With extensive querying and reporting capabilities, you can centrally manage anticipated deliveries and review supplier delivery performance.

SYSPRO's Business-to-Business trading and e-commerce solution contract details can be exported into XML format for electronic exchange with trading partners.

By-Products

By-products in SYSPRO enable you to process the unplanned manufacture of parts from a job. They are defined against an operation in the Bill of Material and can be receipted into stock at any point in the manufacturing process.

Component Fixed Quantity Per

For some manufactured products, the number of components required to make a single parent part is fixed.

SYSPRO caters for situations where the number of fixed components required is regardless of the number of parent parts being made (for example, 1 plate is required to print 10, 100, or 400 business cards), and for situations where the number of fixed components required is related to the number of parent parts being made (for example, one box is required to package every 20 chocolates manufactured).

Co-Products

Co-products in SYSPRO enable you to process the planned manufacture of multiple parts from one job. They are configuring as multiple made-in items against a single bill of material's structure and routing.

Distribution Requirements Planning

Distribution requirements planning in SYSPRO is designed to optimize the movement of inventory in a multi-warehouse environment so that demands can be met effectively and efficiently without relying on excessive stock holdings. Distribution Requirements Planning provides the drivers that enable the Requirements planning module to suggest Supply Chain Transfers from one warehouse to another, rather than a purchase order on an external supplier, or a job on production. Suggestions are based on the closest warehouse in a chain of supplying warehouses, resulting in stock being supplied from oversupplied warehouses to those with a demand. A comprehensive view of the supply chain for each item is available.

Companies in either the wholesale or manufacturing sectors which have regional demand fed by one or more supply warehouses, or manufacturing plants, would typically use Distribution Requirements Planning. The integration between SYSPRO's Inventory, Purchase Orders, Sales Orders, Bills of Materials, Work in Progress and Requirements Planning modules provides a comprehensive view up and down the supply chain.

Kit Issues

You use the Job Issues function to record the issue of items from inventory for a specific job. The quantity entered is subtracted from the quantity on hand and costed at the current inventory cost. The unit cost differs from one warehouse to another. The materials of a kit issue and a specific issue is costed in the same manner. When you do a kit issue you can specify labor costs. These labor costs are added to the material costs to determine the total cost of a job. The total cost can be divided by the quantity to make, which gives the unit price of the manufactured item. Labor is calculated as the hours worked multiplied by the work center rate and reflects the actual hours worked per job.

Load Planning

You can use SYSPRO's load planning to determine when customer orders can be delivered and to improve your picking, planning, scheduling and delivery of orders. Route codes that you configure against each customer (or warehouse for Supply Chain Transfer orders) indicate the load delivery method.

A delivery frequency is associated with each route (for example, every 7 days) as well as the number of deliveries that can be made on a single day. You associate a customer order to a route based on the customer (or warehouse, in the case of a Supply Chain Transfer order) and as each specific line is added to the order, the appropriate route detail (load) is calculated. This calculation is based on the required delivery date, or on the delivery date calculated based on the availability of stock and load capacity. You also specify a route delivery distance (or sequence) against a customer to indicate the order in which the load must be delivered. The loads are managed by initializing them for a selected period ahead, which can be reviewed. Several reports are available to assist in the planning and monitoring of loads.

Serial Tracking

Serial tracking is designed to provide full tracking at transactional level for those items that have serial numbers assigned to them and that may carry a warranty. The serial numbers can either be unique per individual item or the same for a batch of items.

Setup / Teardown

Each operation can have a number of different times specified so that the time taken to setup the manufacturing environment, machinery and work centers to perform the operation and time to teardown the environment down can be accurately recorded and accounted for.

The different times include:

	Set-up time indicates the time taken to ready a specific machine, process or work center for use. No usable items are produced during the setup period. It forms part of an operations elapsed time. Changes
	Startup time is used to indicate the time taken to gradually bring the specific machine, line or work center up to full production speed while producing usable product. It forms part of an operations elapsed time.
	Startup quantity is used to indicate the quantity of product manufactured during the start up period and is deducted from the actual quantity to be manufactured when the run time is calculated.
	Teardown time is used to indicate the time taken to close down the specific machine, line, or work center used in the operation after production is complete. It forms part of the elapsed time. Typically, no usable items are produced during the teardown period.
	Wait time is used to indicate the amount of time between the end of the current operation and the availability of the product to be moved to the next work center. This forms part of elapsed time. Wait time is not included in the calculation of capacity required or in the costing calculations.

Where Used

SYSPRO's Component Where-Used Query enables you to quickly establish exactly where a raw material or intermediary is used within a bill of material structure. It displays all finished products to which the item is attached, including the sequence number, quantity relationship, part category and operation.

Within the Engineering Change Control module, you can use the Where-used Query program to identify all products affected by the raising of an engineering change order for all routes identified as being under engineering change control.

In addition, SYSPRO provides the BOM Replace Where-used program to enable you to quickly replace an item with a valid substitute component in those bills of material in which it is used, which helps streamline the introduction of product design changes.