Process industry

Tags: deal sheet | erp | process industry | SCM | supply chain management

Our projects include capacity forecasting, planning, process modeling and other management issues. The knowledge and experience we gained during past projects ensure that our product suite fits perfectly with the needs of your business.

PearlChain offers a solution with:

Enterprise Resource Planning System (ERP)

At the core of the entire PearlChain concept is the deal sheet, a collection of all the engagements and agreements between customer and supplier where the entire workflow is defined. Deal sheets are a mixture of : who's the customer, what products does he buy, what logistics requirements does he have, do I have to deliver the goods in one central spot or in ten different locations, how can I invoice him, what discounts are we using, etc. All those questions are a nightmare for a traditional ERP application because by their very nature they are an extremely dynamic issue. A deal sheet holds all the details, in real-time and customer and product independent. And PearlChain can implement a deal sheet in such a way that it is identical at both the supply and the demand side - which makes it ideal to connect companies.

Sales orders always refer to a sales deal sheet, from which it inherits all terms and conditions and products to choose from when putting these on the order lines. Order input can be done by means of the sales order screen or automatic using EDI or via a collaborative network.

In a similar way, purchase orders always refer to a purchase deal sheet. The purchase deal sheet represents all terms and conditions your company has negotiated with a supplier. The contract can be standard or call based. If you use the planning module Supply-IT, the system will generate automatic purchase proposals for parts, raw materials and other products for the manufacturing processes. Purchase orders can also be created manually in the system.

For purchase orders, receipts can be registered. The purchase invoice can be matched automatically. The system automatically looks up all open purchase orders of a supplier and looks for a match. If a match is found, the open receipts are closed.

At the end of the production line, the stock in the warehouses is fed in function of the deliveries. The user enters the identification of the production output and the system determines the best warehouse locations for the products. This depends on several product characteristics like dimensions, weight, FIFO or not, order frequency, etc.
Manual input of stock movements covers physical inventory intake, return of shipments, stock replacements, etc.

When the promised delivery date is approaching, the system automatically checks the availability of all planned products. In case the products are available, they can be picked and packed if necessary. The expedition phase can start. Shipments can be prepared and transported. Finally, the deliveries can be invoiced.

All necessary documents are provided by a built-in document management system that integrates your installed base of printing devices with the printing functions of the different Manage-IT modules. It also manages the distribution of e-mails.

All components are based on market-leading, Java-based solutions. Each solution covers a specific technological area. PearlChain knows the possibilities and limits of these technologies from experience.

SCM or Supply Chain Management

The production module allows the entire process of modeling reality, as well as related tasks, task dependencies, Bill of data properties, etc. The Production Planning Module is built around a powerful scheduling engine that draws the optimised scheduling plans.

Production Planning: The 'Material Requirements Planning' or MRP calculates the required materials to replenish the demand, taking into account their Bill-of-Material (BOM). MRP will result in a group of production orders and purchase orders with an expected replenish date. The goal of MRP is to ensure materials are available for all steps in the production flow and eventually for delivery to the customer. This with the lowest level of inventory, taking into account safety stock and reorder point quantity levels.

Production Scheduling: During the CRP run, Supply-IT links the production order to the correct machine or resource, on the best possible time, keeping in mind the capacity of the plant. All production orders are checked according to their urgency as defined during the MRP run. The system automatically plans the steps that are necessary before the next step can be executed. The purchase of material and the production of semi-finished products is planned before the material and products become necessary during the next step in production.

The user can consult the CRP planning in a GANTT chart. In the GANTT chart he can manage and fine tune the planning in the different tab sheets, representing the different departments with their resources. Because of the powerful presentation functions the calculated Gantt charts of the production-, process- and task scheduling can be presented in a user friendly way, with drag & drop functionality so that the planner can make changes manually.

After saving the planning, the released production orders and material provisions are available in Shopfloor.

Shopfloor: In the Shop floor module of Tell-IT, the production departments manage the production orders which have been generated by Supply-IT, the planning tool. Production orders have to be retrieved per department and per resource or machine.

In Shop floor, the warehouse keeper can consult which required materials have to be delivered to the different production resources at what time. It is possible to work with split orders or total orders.
The quality engineer can consult the list of production orders which have been completed. He can register the execution of the quality control.

Benefits of working with PearlChain

• The same tool and data set is used for all production planning. This data is updated continuously and calculated throughout the process. At the beginning there is only basic data available, but over time more and more information is added and incorporated. This way planning becomes automatically better, more accurate, and in real time.
• The calculation of MRP and CRP is done dynamically and in real time throughout the entire supply chain (Finite Capacity). The information is always up to date.
• Planning is Event Driven, which means that any major change is automatically passed through the entire value chain. Events may result from operations, sales, purchases or other functional departments.
• The planning is "Memory model" driven: because the processes are executed in the internal memory, the performance and speed of the system is guaranteed.

We offer your company a multifunctional tool, which allows you to optimize your management, from enterprise resource planning to the entire strategic planning.