The globe, manufacturers are searching for new, creative ways to address the growing demands of global manufacturing. They want the latest tools and technologies to boost performance from their operations, suppliers, partners, distributors, and extended ecosystem, and they need global views for better visibility both internally and across the extended supply chain. Besides, operations must move information more effectively to gain real-time insight.
Key Challenges in Manufacturing
- Analysing actual productivity
- Exact utilisation of resources
- Quality Management
- Demand Based production
- Handling Unit management
- Batch management
Manufacturing: A specific SAP set-up developed by our experts, for Manufacturing Industries
We have considerable experience in implementing SAP in Manufacturing Industries. We have Subject Matter Experts who understand the Business processes in Food, Beverage, Engineering and Process Industries.
Recommend and Implement different Planning strategies under
- Make to Stock and
- Make to Order; Planning in multi Plant environment.
Materials Requirement Planning
Plant and MRP Area level MRP; Enhancements to MRP; Enhancements to Stock/Requirements Report. Employing different MRP types; Effective use of MRP parameters in Configuration and Master data for planning with precise quantities and dates to meet the Business Requirements, Handling order and lead time fluctuations using Static/Dynamic safety stock, safety lead time
Production Planning – Discrete
Production Planning using Production Orders for discrete manufacturing; With and without Batch management. Integration with HU Management, Warehouse Management
Production Planning – Repetitive
Production Planning using Planned Orders for Repetitive manufacturing; With and without Batch management. Integration with HU Management, Warehouse Management
Production Planning – Process
Production Planning using Process Orders for process industries; With and without Batch management. Integration with HU Management, Warehouse Management
Kitting of the Product subsequent to manufacturing either
- own plant personnel or
- subcontractors; Kit to stock, Kit to Order.
Managing Batches in Inventory, Batch Determination, Linking Vendor Batches to manufacturing, Traceability of bathes delivered and their origin; Documentary Batch management: which eliminates the need for managing inventory in batches but provides info on “Where Used” at consumption points, Batch Status Management to restrict the Goods movement of material inventory of certain batches
Rev level Management
Interchangeability of Materials with Rev level change; Customer Initiated Reve level change management. Switch over from OLD to NEW revision of Finish Good or Component may result in unused OLD stock. GETR has alternate solutions to Handle these scenarios to ensure the wastage is minimized/eliminated
Material Staging to Production
Recommend and Implement different strategies for transfer of stock from Source to Work Centres. The sources include Storage Location, Warehouse, Different Plant, External supplier; Solution may include Use of Radio Frequency Scanner, KANBAN etc. depending on the Business Requirements
Handling Unit Management
Effective use of Handling Unit Management and its integration with Production, Warehouse, Outbound and Inbound Logistics; Automatic Packing function using Packing Instructions, Handling Partials and Batches in Handling Unit; Club Packing etc.
Cross Docking from Manufacturing to Shipping
In case of products with SHORT shelf life, Transfer of product to sister companies at the next door etc. there is no need to transfer the stock to the warehouse; Instead, the produce can be X-docked at the Shipping area. GETR developed and successfully implemented custom built solutions which optimizes the material handling
Interface to External Systems
Develop interfaces to
- External Manufacturing Execution systems,
- Material Handling Robotic systems,
- Automatic Storage and Retrieval Systems (ASRS),
- Carousels (for storage and retrieval)
Develop interfaces to 3PLs with visibility of Inventory, Inbound and Outbound movements
RF Scanner based material movements
GETR built custom RF transactions for movement of stocks on Shop floor; These are user friendly and fool proof. The use of RF can be in SAP WM or SAM IM environments depending on the Business Requirements.
Physical Inventory at Storage Location level using Tags
GETR developed and successfully implemented custom built Physical Inventory (end to end) solutionin Manufacturing Plants where SAP WM is not implemented, In the absence of inventory management at Storage Bin level, Paper tags are considered for identification of inventory; Wall to Wall Physical Inventory is carried out using the counted info on the Tags; A Dashboard with all functions is built to cover the End to End process and Reports
Why Choose GETR
We understand manufacturing industries have unique requirements and we also understand the pain points and speak your language.
We have expertise to address these areas to improve your business process.