SYSPRO for Machinery and Equipment provides solutions to support lean manufacturing and cost efficiencies, and to enable responsiveness to global market fluctuations.
SYSPRO offers easy integration with computer aided design and manufacturing systems (CAD and CAM), and permits full traceability through all transactions, enabling the reduction of inventories and improved capacity utilization. SYSPRO's Engineering Change Control module augments or eliminates the paper trail that traditionally accompanies changes to product design data, while SYSPRO Factory Scheduling facilitates the management of the supply chain, from planning and execution to the identification and remediation of potential problems. In addition, SYSPRO Assets Register addresses the asset intensive nature of the industry by providing planning and control tools for capex expenditure and asset depreciation.
From enabling the identification and tracking of non-value adding activities inherent in your current operational processes, to the automation of manual processes, SYSPRO's powerful functionality provides you with the tools to implement your LEAN initiatives. Its integrated nature and ease-of-use facilitates the effortless extraction of financial and operational information required for Value Stream Mapping (VSM).
SYSPRO's Inventory module is a synchronized hub providing a consolidated view of all stock locations and those activities that impact inventory optimization and customer service levels, as well as the end-to-end elements of costs and lead times. Features such as Pareto and obsolescence analysis can assist in identifying those products that are suitable for VSM focus, while SYSPRO modules such as Engineering Change Control, Bills of Material, Work-in Progress and Factory Scheduling facilitate the evaluation of targets for kaizen programs, such as reduction in design and manufacturing costs, cycle times, queues and setups.
SYSPRO's powerful inspection, serial tracking and lot traceability functionality aid in the identification and tracking of the source of defects, thereby enabling the implementation of kaizen initiatives towards the principle of 'Quality at the source'. The queries and reports in Work in Progress enable you to quickly assess the statuses, inventories and costs associated with work in progress, and provide metrics on utilization, efficiency, scrap and rework, while customer and supplier delivery performance metrics are provided by SYSPRO's powerful sales order and purchase order functionality.
SYSPRO's Inventory and Bills of Material modules enable the modelling of the LEAN techniques of batch size and setup reduction on costs, lead time and inventory. SYSPRO's Factory Scheduling provides graphical tools to assist you in optimizing your scheduling and sequencing processes, to reduce setup and overall lead time, and improve manufacturing flexibility and sale-to-customer flow. This, along with the inventory optimization and production planning features, enable you to refine the pace of production to match the pace of sales. Furthermore, features such as sales order / job / purchase order linking facilitate the electronic implementation of true pull supply chain processes where appropriate.
SYSPRO's Document Flow Manager and SYSPRO e.net solutions enable you, not only to automate resource and time-intensive processes such as order processing, but also to handle increased volumes from global customers by providing order taking and acknowledgement on a 24/7 basis, thereby improving lead time and freeing up staff to perform other value-adding tasks. Furthermore, SYSPRO's XML-aware solutions enable version-independent integration with best-of-breed shop floor monitoring and control systems.
The system's sophisticated reporting and analytics tools enable user-defined reports and queries, while its powerful customization functionality enables the creation of efficient workflows to implement business rules and standardize business processes. Additionally, the Office Automation and Messaging module enables the automatic raising of alerts, triggers and events, based on user-defined criteria, thereby aiding prompt problem solving and process improvement.
SYSPRO's flexible integrated features and best-practice focus give you single-point visibility and control, providing support for the implementation of your LEAN initiatives.
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.
In 'to-order', as well as project and service environments, job cost accuracy is essential in attaining correct pricing and profitability, as well as to assess the reliability of the quoting process, while in standard costing environments, it is essential for tracking the validity of current standard costs.
For 'to-order' environments, SYSPRO's Quotations module enables detailed estimates based on all aspects of the job (or jobs) and the automatic creation of jobs, purchase orders and sales orders based on approved quotes. This ensures the integrity of the quoted and margin information throughout the system. For project and service environments, this same functionality is available with the added benefits of hierarchical analysis of costs and margins per head and section.
SYSPRO's fully integrated solution enables the capture, tracking and analyzing of job and product costs and profitability in real-time. Details of expected versus actual costs for material and scrap, internal and external labor, fixed and overhead costs per job, or group of jobs, is available through SYSPRO's powerful querying and reporting features. This enables the identification of exceptions and problems as they occur, such as areas of high cost expenditure, production scrap and rework, and problems in the quoting process. Furthermore, for those businesses wishing to take advantage of government and private enterprise grant programs, detailed R&D job data is easily extracted for regulatory reporting requirements.
With SYSPRO's visibility to product cost details and profit margins, including for co and by-products, you can evaluate job cost performance, margin analysis and pricing with confidence.
Increasing manufacturing efficiency means getting the right balance between demand and supply, while optimizing capacity, improving throughput, and reducing waste and variable costs. SYSPRO provides interactive decision support tools that give you visibility and control over all inputs and outputs.
The Material Requirements Planning system gives you an integrated picture of your demand and supply, as well as your available capacity, enabling you to model what-if scenarios to produce viable replenishment and production plans. SYSPRO's Factory Scheduling assists you in maintaining accurate and up-to-date production schedules that take account of the complexities of your factory. This enables better co-ordination between work centers, increases productivity, reduces work in progress and achieves better customer service levels.
Material and labor tracking, as well as cost, scrap and utilization management is facilitated through SYSPRO's Work in Progress module, which enables you to track in-process production at every stage and identify problems as they occur.
One of the key contributors to maintaining a competitive advantage in the global market is the ability to deliver quality products to customers within their expected delivery date, in a shorter time than your competitors, and within your cost constraints. To do this, you need to be able to analyze lead time constituents and non-value-add activities, from order taking to delivery, so you can identify and eliminate waste. SYSPRO's integrated nature gives you complete visibility across the entire supply chain, enabling the co-ordination of activities, while its powerful tools help you to monitor and improve lead time performance.
SYSPRO e.net solutions and import functions facilitate improved electronic collaboration with your customers and suppliers, thereby reducing the time and margin for error for activities such as order processing and the creation of customer-specified designs. Supplier performance data provides you with comparison of original due date to receipt date for purchased items, while the capture of customer request date at order entry time enables reporting on customer delivery performance by customer, by order line.
For engineering or build-to-order items, SYSPRO's Quotations module enables the capture of all build details and costs, thereby enabling you to calculate realistic delivery dates. It also facilitates the quick conversion of an accepted quote into the relevant details in Work in Progress, Sales Orders and Purchase Orders. This reduces capture time and errors, as well as the time taken to raise the paperwork.
For stocked items, SYSPRO enables the capture of standard purchasing lead time for components, as well as the automatic calculation of manufacturing and cumulative lead times for manufactured product based on the elements of operation times in the Bill of Materials and Quotations modules. At the design stage, the Engineering Change Control module helps you streamline and control the product design process, helping to reduce the time from concept to market.
Material and distribution requirements planning helps you identify what you need and when you need it based on standard lead times dynamically adjusted for batch size for selected sources of demand and their requirement dates. Powerful queries provide pegging and time fence information to enable effective decision-making.
Work in Progress job data provides job and operation planned and actual start and finish dates, which enables you to identify bottlenecks in production. In addition, SYSPRO Factory Scheduling provides excellent visibility to your production scheduling activities, facilitating improved use of manufacturing resources.
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.
Archiving provides a mechanism of storing data that would normally be delete from the system, thus enabling non-current data to be removed from day-to-day files, but to still be accessible, through the standard query programs, should the need arise. Instead of merely deleting data at the time of performing a purge routine, SYSPRO creates a file in XML format that contains the purged data. This data is stored in a pre-defined location that can be queried using the standard Query programs. Within SYSPRO, you can archive the following: Sales orders, Jobs, Engineering change control bill of materials.
The Capital Expenditure Budgetary and Control system (Capex system) is a sub system within the Fixed Assets module. The system will allow users to budget for, and manage Capital Expenditure items, for the current financial year, and future financial years. A Capex item could include one or more Capex requisition lines. Each Capex item will have a budget recorded against it, and as soon as Capex requisition lines are captured for the item, the system will record uncommitted, committed and spent balances against it. The user will be able to manage and control both Capex items and Capex requisition lines by status, being unapproved, approved, on hold, and closed. Once a requisition line is approved a Purchase Order or Works order can be raised for the item. On receipt it becomes a normal Asset.
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.
Cumulative lead time represents the longest path in the bill of materials, including raw material purchasing and manufacturing lead time. It is established by reviewing the lead time for each bill of material path below the item; whichever path adds up to the greatest number defines the cumulative lead time.
Within SYSPRO, the cost of any stock item is stored as the item's inventory warehouse cost, using either the average, standard, FIFO, LIFO or last costing method. The material, labor, subcontract, fixed overhead and variable overhead costs of a manufactured stock item are stored against a manufactured item's bill of material and these costs are rolled up through all levels of the bill via the Cost Implosion program, to provide the item's expected manufacturing cost. Within SYSPRO's Work in Progress module, the estimated costs of a job are calculated from the manufactured item's bill of material cost, while the actual costs of the job are recorded as you issue material and labor to the job. When a job is complete, you can receipt it based on expected or actual costs and post any variances to the relevant ledger codes.
You can opt to enter material costs for the lowest level stock items manually against each bill, or transfer these costs automatically from the inventory warehouse costs. The Cost Implosion calculations are performed starting from the lowest level of the bill of material and take into account the various elements of production time, labor rates, productive units, economic batch quantities and scrap quantities and percentages.
Within the Bill of Materials module, you can also perform what-if costing, by changing elements of the bill of material costs and performing a what-if roll-up.
Within the Quotations module, estimates are held as bills of material for non-stocked items and you can perform various roll-ups to establish the cost of the made-in item.
Material requirements planning assists you in planning and creating realistic production, purchasing and supply transfer schedules, and maintaining optimal stock holdings in a multi-warehouse environment. It nets-off supply against demand and calculate future material positions, suggesting changes or new manufacturing, purchasing and transfer actions to satisfy the demand.
When a job is created as a direct result of a Customer order, a link is created between the sales order line and the job to enable the sales order line to automatically be released on job completion and to prevent inadvertent changes to the sales order line.
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.
What-if costing is used to simulate the consequence of changing your individual bought out items costs, material costs and Labor costs without affecting existing costs held on the system. Labor costs are changed by altering the what-if work center rate indicator held against each operation. Once what-if costs have been entered the BOM Cost Implosion program can be used to re-cost stock items from raw material level through to the finished product.