Throughout the production process all materials used and produced are traced by serial numbers. Especially, but not only, medical products require the full tracability from the raw material acquired from a vendor till the finished product. The standard ERP reporting is not adequate enhough to have a speedy and thorough overview of required data. Data extracted from the ERP combined with an in house developed project for quality rejections & follow up (internal, customer & vendor related), is presented in a dashboarding way combined with a detailed view for several datasets.
Working Hours: Hyper Analyzer delivers daily an overview of multiple past months detailed activity on the workfloor. Hours performed on workorders as well as quantities produced are stored in the dataset. The dataset is extended with the HR performed hours per employee. Extensive reports are put in place and can be altered by the production staff to measure performance, efficiency and rentability.
Scrap & material losses reporting: To have a clear follow up on scrap and losses figures, a dataset is created that holds not only the performed production consisting of material use and parts produced, but also the theoretic consumption allowed according to the amount produced. This dataset can be used to pin point the moments where components are wasted and allow tackling the issues. This dataset also is linked to the P&L figures where accounting variances on material loss can be compared with actual production figures.
The figures generated in the ERP system that were previously cumulated and exported to be uploaded in the accounting system can now be analysed in detail. A dataset was build to include all detail general ledger transactions. For instance P&L material losses can now be traced back to the most detailed information.
Based on the current stock in the ERP system and MRP calculations a Hyper Analyser dataset is build which gives the possibility of analysing future stock situations on any date required. Not only that, analysis can also be done on the reason of the demand on any leve, for instance the reason of a purchase requirement can be broken down into it's source, i.e. sales orders, forecast and many others.
Daily planning: On the basis of the MRP ERP Workorder information and detailed planning made in the HR system, datasets are made for analysis of workload and machine/personell availability. A link between data stored in database from different vendors is made with Hyper Analyzer on a daily schedule.
Long term planning: Future demands resulting from forecast and open salesorder are combined with bill of material data stored in the ERP system. As a result, the planning department has a detailed overview of future machinal and human resources needed.
Based on the data available in the MFG-PRO ERP system and combined with data provided by the sales staff, supply chain team and financial department, several datasets are created to have in detail past and future predicted sales figures analysis. Combined data are "open sales orders" and "invoices" extracted from the ERP system, "forecast figures" entered by the salespersons in dynamically created Excel files, "statistical forecast figures" generated by the logistics team and the plan figures made available by the financial department. The project complexity came from the combination of requirements based on the specific work of sales person with off line connectivity and the on site data maintenance of the ERP system.