Production Planning module (PP) SAP ERP Solutions for garment and textile industry, included: BOM (Bill of aterial),Routing,MPS (Master Production Schedule),Production Order
SAP solutions have been customised by Attune, SAP Partner, and they run on only one platform. So, this solution is suitable for ABC CORP, which have both garment and textile manufacturing.
BOM (Bill of Material):
Bills of materials (BOMs) contain essential master data for integrated materials management and production control. In the design department, a new product is designed such that it is suitable for production. The result of this product phase is drawings and a list of all the parts required to produce the product. This list is the bill of material.
Because Textile manufacturing and Apparel manufacturing have their own industry-specific requirements, SAP designed many BOM styles which is suitable for industry-specific.
With SAP AFS, materials contain information about colours, sizes and qualities that are stored in grids and categories, Apparel BOM is also managed in grids, and user can store the component consumption at grid level in the BOM.
Processes management from production order to finish goods
Routings enable you to define the route for production of materials (products). Therefore, routings are used as a template for production orders and run schedules as well as a basis for product costing.
In a routing you can plan:
- The operations (work steps) to be carried out during production
- The activities to be performed in the operations as a basis for determining dates, capacity requirements, and costs
- The use of materials during production
- The use of work centres
- The quality checks to be carried out during production
A trigger point is an object that can be assigned to an operation to trigger certain functions. Trigger points functions help user to reduce repeatable works.
Capacity management will manage machinery power and labour power to calculate the responsibility for each contract.
MPS (Master Production Schedule)
ABC CORP may have many styles of manufacturing, such as contract manufacturing, make-to-order, and make-to-stock. Contract manufacturing, make-to-order, and make-to-stock environments require different material planning philosophies for production processes. In a contract manufacturing or make-to-order production environment, specific customer requirements form the basis for production planning, whereas a make-to-stock production process can be based on forecasts or dependent demand. Beside that, textile and garment have their own characteristics in production planning. SAP solution supports them all with a lot of planning tools, such as capacity planning, sales order planning, material requirements planning, advanced planning operation, cutting planning,…
Advanced planning and scheduling methods in SAP for Mill and SAP AFS include a number of tools to handle distribution, deployment, transportation, production planning, and shop floor scheduling.
Planning base on characteristics of products is extremely important to textile products. For example, a company may benefit from scheduling a dying machine to colour all products red on one day, yellow the next day and so on. By designating primary characteristics such as colour, dimension, weaving technique… you can plan schedules so that characteristic take precedence over the product. This is often called block scheduling, a special scheduling function for Textile industry.
Production orders are used to control production within a company and control cost accounting also. A production order defines which material is to be processed, at which location, at what time and how much work is required. It also defines which resources are to be used and how the order costs are to be settled.
The production orders in AFS contain AFS-specific data (grid values and categories) to meet the requirements of the textile and apparel industry. Using the production order in AFS you can carry out the production with bundles.
Thecritical path management deals with the pre production control area . The sales order goes through a number of activities like , fit approval , costing , RM processing before being actually taken up for production . A strict control on these areas are required to get the production system running on time to keep the delivery schedules
The critical management paths helps to get the pre production activities on time.
Product Cost Controlling
This function helps to calculate the cost of goods manufactured. The costs may then be analyzed and business decisions (such as “make or buy” decisions) made.
In AFS, the costs of the produced stock keeping units (grid values and categories) of a product are therefore sometimes very different. It is at times not sufficient to carry out the product costing and valuation at material level for AFS products. With the AFS System you can cost the production costs of a product at the level of produced stock keeping units.