Below are our regional Head Office contact details. For full contact details for all offices in a region, click the region name.
Tel: +27 (0) 11 461-1000
Tel: +1 (714) 437-1000
Tel: 02 9870 5555
UK and Europe
Tel: +44 (0) 161 876-4498
Key Features and Functions
Accommodating variable end-products which result from re-grading and unpredictable chemical processes
SYSPRO's solutions provide the tools such as Work in Progress to record the inspection details of manufactured products and, depending on the results, select to receipt, scrap or rework quantities.
- Using SYSPRO's co-products and manufacturing inspection functionality, you can easily cost and capture the receipt of multiple products of varying grades from jobs originally planned for single-grade items. You can choose to apportion costs between materials and co-products according to a percentage breakdown for total material, operation and sub-contract cost, or you can define percentages against specific operations and materials.
- Within the inspection function, you can capture detailed records of counts, inspection, scrap, rework and stock receipts. You can receipt inspection products as the original product to manufacture or as a different product, or products, which is useful for end-products of variable grade. Also, you can receipt items into a different warehouse from the one that was originally planned.
Particularly useful for companies operating in highly price-competitive and margin-pressured environments, as well as for manufacturers dealing with extreme fluctuations in raw material prices, actual cost tracking operates in addition to and separate from your designated costing method of Average, Standard, Last, FIFO or LIFO. It enables you to monitor the actual costs of a batch-serialized or lot-traceable item for all item movements, thereby providing improved accuracy for job-cost estimating and product pricing.
The SYSPRO Advanced Scheduler allows you to generate accurate production schedules through the use of advanced scheduling rules and by factoring in component and raw material availabilities.
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.
SYSPRO Amendment journals provide an audit trail of any changes made to Master data. They contain a date and time stamp, the data before and after the change as well as operator information of who effected the change.
SYSPRO enables you to record a list of manufacturers whose parts you are prepared to accept when ordering a specific SYSPRO part. You define (per stock item) the specific manufacturers' part numbers that are acceptable. This ensures accurate purchasing, and provides the facility to link a specific supplier to a preferred manufacturer. When ordering parts, you can show a list of alternatives, based on the approved manufacturers list. These can be restricted by supplier, if required. Search options are available to enable the SYSPRO equivalent stock code to be located from a manufacturer's part number.
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.
Within SYSPRO you can add new assets directly to the assets register or process them through the Assets Capex system. For the latter, the asset acquisition is simplified through a user-friendly suspense review facility. It enables you to retrieve and check the details of an asset receipted from a purchase order or job before automating its transfer to the live asset register, thereby reducing double entry, as well as the margin for capture errors.
The asset disposal function facilitates the efficient processing of asset disposal transactions, including amounts received, costs incurred and the profit or loss on disposal. You can also assign a reason code for disposal analysis reporting.
Whether revaluing assets to meet International Accounting Standards (IAS) or Generally Accepted Accounting Practices (GAAP) requirements, or because the current intrinsic or market value differs substantially from the net book value of the asset, SYSPRO provides a fast and easy means of raising the necessary revaluation reserve and accumulated depreciation adjustment entries.
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.
SYSPRO facilitates the calculation and posting of both book and tax value depreciation with full auditability, and includes the option to start calculating depreciation for each asset from the date of purchase or from a designated depreciation start date.
The system caters for a variety of depreciation methods including Straight Line, Reducing Balance, Statistical End of Useful Life (EUL) and Fixed EUL, as well as up to 14 variable depreciation rates. Periodic depreciation is calculated automatically with the option to run the calculation in 'Report only' mode for verification purposes.
Useful for when the wrong depreciation code has been applied to an asset, the depreciation adjustment facility allows secure alteration of depreciation amounts and generation of the relevant general ledger entries. Furthermore, to meet the regulatory requirements of International Accounting Standards (IAS) statement 16, SYSPRO provides the facility to enter the revised life capacity of an asset and to calculate the necessary adjustments to accumulated depreciation and depreciation for the year.
When you take on a new assets register from an external system, either manually or via the import function, SYSPRO facilitates the optional automatic calculation of depreciation for those assets which you acquired before the start of the current financial year.
Asset events provide the ability to send alerts or trigger additional programs when capex budgets have been exceeded under certain conditions, or the minimum book value of an asset has been reached. Such alerts can serve as useful automated reminders to, for example, consider revising capex budgets, revaluing an asset, or revising the useful life of an asset.
Good corporate governance entails regular asset stock takes to verify the existence and location of assets. SYSPRO provides the facility to select and capture asset counts by a variety of selection criteria and to print exception reports to identify actions required.
User-defined label formats enable the printing of count labels along with barcode attributes for easy capture and count details, including identification and serial numbers. Counts can be captured manually or electronically.
On confirmation of the asset count, asset transfers will be generated if applicable. Asset write-offs for damaged or missing assets highlighted in the exception report are easily processed using the asset disposal tools. An Asset Count provides the facility to select a range of assets to count, capture the results of the count, produce an exception report and confirm the count.
Asset templates enable you to simplify and control the input of information for new assets by defining default values for different types of assets. You can create templates at asset branch, cost center and group level. The values defined are defaults only and may be overridden at the time you take on a new asset or transfer an existing one.
The At a Glance queries in SYSPRO display key summary information of your sub-ledgers for the current and previous two financial periods and provide quick reconciliations of sub-ledger totals to general ledger control account balances. The queries provide information such as inventory valuations by warehouse, receivables and payables values by transaction type within branch, balances by bank, work in progress valuation and current general ledger totals. In addition, each query shows the current posting period as well as the next audit trail numbers, such as journals and register numbers.
There are numerous Audit trails in SYSPRO, from Job Logging, which provides a record of every program accessed by an operator, to journals of transactions processed, to Amendment Journals of all changes made to master data.
Automated document flow provides a powerful way of automating your business processes and forms a key part of facilitating collaborative commerce by enabling SYSPRO customers to exchange documents (e.g. sales and purchase orders) electronically.
Incoming documents (defined using XML data) can be tracked and automatically posted into SYSPRO. Documents can be transformed from one format to another using either the Document Flow Manager itself, or more sophisticated products such as BizTalk.
The Automatic Bank Reconciliation program allows for cash book entries (deposits and withdrawals) to be automatically reconciled to the corresponding bank statement entries using an import file, thereby reducing time spent on labor-intensive manual processes.
The Automatic Bank Reconciliation program allows for cash book entries (deposits and withdrawals) to be automatically reconciled to the corresponding bank statement entries using an import file, thereby reducing time spent on labor-intensive manual processes.
Note: The format of the bank statement import file is stipulated by SYSPRO (see the SYSPRO Help against the Automatic Bank Reconciliation program). If the statement file from the relevant bank is not in this format, then an intermediate step is required to convert it. Conversion programs for the more common banks in the different regions exist but not for all, so a conversion program may need to be developed depending on the customer's bank.
Particularly useful for applying a customer payment against a large number of account transactions, the Automatic option in the Accounts Receivable Payments and Adjustments program applies the payment amount based on invoice number or date sequence, taking into account available terms discount. You can also select to add any unapplied credits to the payment amount before applying it to the transactions.
SYSPRO's available-to-promise (ATP) feature helps make reliable delivery promises to your customers, by showing you that portion of your inventory and planned production that is available to fill their orders and on which dates. You can choose between regular (discrete) and cumulative modes of display and can define which components of supply and demand should be included in the calculation.
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.
Batch forecasting is used to forecast the bulk of a company's stock codes, whereas manual forecasting provides for forecasting of items on an individual basis and is used for those items that require closer attention (e.g. A class items, new items with no history and items that are difficult to forecast).
SYSPRO enables you to create a bill of jobs (automatically or manually) for all made-in components that exist in the product's bill of material chain. This is particularly useful in a make-to-order environment where a customer order is received for a product whose components include other made-in products for which jobs must be raised. Creating a bill of jobs enables you to view the links and progress of related jobs, as well as to query and report on the rolled up costs.
When a Bill of material is changed and accepted, using the engineering change control facility, the previous revision/release of the bill can be archived automatically or manually, using the standard SYSPRO archiving facility. This archived bill can be accessed at any stage using the Structure and Routine program
Blanket purchase orders enable you to create, maintain and use contract purchase orders as well as monitor purchase order receipts against a supplier's contract.
The purpose of these contracts is to allow a fixed price to be recorded for a specified period and/or volume, plus an agreed delivery schedule. With extensive querying and reporting capabilities, you can manage anticipated deliveries centrally and review supplier delivery performance.
SYSPRO's Business-to-Business Trading features enable the export of contract details into XML format for electronic exchange with trading partners.
The practice of Businesses trading directly with other Businesses electronically is called Business-to-Business Trading. Within SYSPRO this is facilitated through a number of different Import/Export programs as well as SYSPRO e.net solutions.
The by-product feature in SYSPRO enables you to process incidental parts or materials created by the manufacturing process. By-products are defined against operations in the bill of material and can be receipted into a product or waste warehouse at any point in the manufacturing process.
Using either SYSPRO's import facilities or e.net solutions, you can seamlessly integrate your CAD designs with SYSPRO's Bills of Material. This removes the need to recapture, thereby saving time and reducing the possibility of transfer errors. Additionally, you can use SYSPRO's multimedia features to link objects such as drawings, designs, certificates and video clips to part numbers, to inform production staff and provide them with quick links to the relevant paperwork.
To determine production and capacity requirements, you must have visibility to future demand and to the resources you have available to deal with that demand. SYSPRO provides extensive demand management capability with its forecasting, and families and groupings functionality. These features enable you to refine your predictions of future sales based on past history, trends, seasonality, Pareto analysis and other non-quantitative factors, as well as to closely track forecast errors. Forecasts in SYSPRO are derived via algorithms which analyze"”at SKU, family or group level"”the history of sales values, gross profits, cost of sales, quantities sold and sales hits.
SYSPRO's Master Production Schedule provides a complete demand profile for master scheduled items out to the planning horizon, via a combination of approved forecasts, customer orders, and other demand created by order point replenishment policies. This demand profile is then exploded through all levels of the bill of materials via the requirements calculation using infinite capacity to determine detailed time-phased production, material and capacity requirements. Planners can then use the resulting jobs as input to whichever scheduling tool within SYSPRO is most suited for modeling their capacity and scheduling requirements.
SYSPRO Factory Scheduler enables you to build a complete profile of your factory capacity by facilitating the definition and modeling of capacity loads around multiple constraints such as machine availability, efficiencies, relative efficiencies and utilization; labor shifts and calendars; tooling; and in the advanced scheduler, around material availability for bills of jobs. Sequence dependent changeovers, transfer quantities and operation make span and slack times are all catered for.
SYSPRO Factory Scheduler caters for the definition of finite resources, such as lathes, which have the capacity to handle only one job at a time, or infinite resources, such as ovens or drying rooms, which have the capacity to handle multiple jobs in parallel, and includes the capability to designate resource states and preferred resources. Furthermore, it enables you to define capacity based not only on machine availability, but also on the characteristics or match properties, such as firing temperatures, of the product being scheduled.
SYSPRO provides a powerful cash-flow modeling tool which enables you to create multiple cash-flow models based on optional inflow and outflow criteria from receivables, payables, cash book, general ledger, purchasing and sales. The Cash flow Forecasting model enables you to view the company's projected cash position into the future by applying outstanding payables (cash requirements), receivables (payment projections) and other cash projections to the current bank balances. The information is presented in graphs and listviews in customizable panes.
Change control facilitates the revision to a drawing or design released by the engineering department. SYSPRO's Engineering Change Control module helps you to control the changes to modify or correct a part and provides full workflow and tracking of change control activities.
Within SYSPRO, you can use a free-format or a structured chart of accounts. A structured chart of accounts gives your company the ability to store, protect and query data in complex structures within the General Ledger system. This structure can be separated into a series of pre-defined sections, such as branch, department and cost center, thus allowing for analysis at each level of the structure.
Co-products in SYSPRO enable you to process the planned manufacture of multiple parts from one job. They are configured as multiple made-in items against the structure and routing of a single bill of material.
Commitment accounting in SYSPRO enables improved budgetary control over service-related and non-stocked purchasing costs. Both uncommitted costs from purchase requisitions and committed costs from purchase orders can be included for comparison against budgets for the relevant ledger codes.
You can configure SYSPRO to either reject or warn against processing those purchases that cause the budget to be exceeded. The Commitment Query provides a quick snapshot of uncommitted, committed and actual costs, as well as a comparison to period and annual budget values.
SYSPRO caters for situations where the number of components required is fixed regardless of the number of parent parts being made (for example, 1 plate is required to print 10, 100, or 400 business cards), and for situations where the number of fixed components required is related to the number of parent parts being made (for example, one box is required to package every 20 chocolates manufactured).
SYSPRO enables you to specify at what point in a job materials are required: job start or operation start. If you select the latter, you can indicate on which production operation a component or raw material is required, thus facilitating just-in-time material requirements planning. Material allocations are pegged to the start of the operation, rather than to the start of the job, thereby helping to reduce unnecessary inventory and work-in-progress.
The Component to Parent Tracking feature enables you to implement the tracking of all serialized/lot traceable components/materials used in the manufacture of a product. It allows for the tracking of component/material serial and/or lot numbers issued to a job to make a serialized and/or lot traceable parent product. In this way it provides one-to-one tracking between the component serial/lot numbers and the parent serial/lot numbers for quality testing and targeted recall purposes.
SYSPRO's Component Where-Used Query enables you to quickly establish exactly where a raw material or intermediary is used within a bill of material structure. It displays all finished products to which the item is attached, including the sequence number, quantity relationship, part category and operation.
Within the Engineering Change Control module, you can use the Where-used Query program to identify all products affected by the raising of an engineering change order for all routes identified as being under engineering change control.
In addition, SYSPRO provides the BOM Replace Where-used program to enable you to quickly replace an item with a valid substitute component in those bills of material in which it is used, which helps streamline the introduction of product design changes.
Useful for improving the time taken to process quotations and orders for commonly sold configurations of configure-to-order products, SYSPRO's Product Configurator libraries enable you to store and rapidly retrieve specific configurations. During quotation or order processing, you can simply select the relevant library code instead of going through all the selection criteria and options with your customer.
Selection criteria can be used to decrease the number of options/components/operations that can be chosen by the person running a product configuration. This is done by linking options/components/operations to selection criteria. By selecting color, for example, the operator could choose from the criteria red, blue or green. The rest of the components and operations would then be dependent on the color chosen. The Invalid Selection Criteria feature enables the linking of selection criteria in such a way that, if a criterion is chosen (during configuration), all subsequent criteria linked to that choice are not available for selection. This prevents the selection of invalid combinations and ensures that the configuration functions correctly.
One of the many pricing features available in SYSPRO, the Contract Pricing sub-system enables you to configure prices for time-specific specials and promotions against selected customers, with the contract prices taking precedence over all other pricing methods for the specified period. Various contract pricing methods are available, including flat price, quantity discount breaks, cost markup and price less percentage.
You can configure prices at either customer or buying group level based on a range of selection criteria such as stock code and product class. Using buying groups enables you to apply a single contract pricing method to a group of customers, thereby precluding the need to maintain contracts for each customer individually, whilst the import/export features facilitate the quick formulation of prices in spreadsheets outside of SYSPRO when a number of contracts change.
Constant innovation through on-going research and development to formulate new and better products, is integral to your industry. Our rules-based electronic workflow system with full version control, security and auditable history enables you to streamline and apply strict control over your design-to-market processes.
SYSPRO software provides the tools to enable you to implement all the controls necessary to ensure that your products are manufactured under consistent processes, to the correct formulae and specifications.
- SYSPRO's Engineering Change Control (ECC) enables you to streamline and apply strict control over your design-to-make processes by providing a rules-based electronic workflow system with full version control, security and auditable history.
- SYSPRO ECC also gives you the tools to record and track new and modified product formulae and process changes, assess the impact of these changes on costs and associated data, and control the change routing and approval processes.
- SYSPRO ECC’s queries, audit trail, history and archive facilities give you quick online access to details of prior product versions, as well as the option of reverting to the production of an earlier product version if required.
- SYSPRO solutions cater for single-level, multi-level, co-and by-product bills. Flexible bill definitions accommodate complex raw material and intermediary requirements to ensure precision in quantities required for bulks, batches and packs. Precision is further enhanced by SYSPRO's allowances for high tolerances in quantity definitions, as well as accommodating the number of levels in a multi-level bill.
The Copy Estimates facility saves you time when setting up new estimates by enabling you to quickly copy (in review or automatic mode) operations and/or components from another estimate, a stocked item or from an ASCII file. Additionally, you can define how you want the new operations and/or components inserted if the estimate has existing component and operation records.
The Copy Hierarchies facility saves you time when setting up new hierarchies by enabling you to copy from an existing standard hierarchy and thereafter make changes as required.
SYSPRO's Cost Implosion facility provides an automated cost roll-up through all levels of the bill of materials which enables you easily implement accepted cost changes. Its powerful 'what-if' costing tool enables you to model the effects on your profit margins of proposed or theoretical changes to cost elements, such as raw material, labor rates and fixed and variable overhead rates, and to optionally transfer new costs to the relevant products in the relevant warehouses.
SYSPRO Cost Rollup feature enables you to query the calculated material, labor, fixed overhead, variable overhead and total costs of a stocked manufactured item in the Bill of Materials Costing Query without having to run the Cost Implosion.
The Cost Rollup is also used in Quotation and Estimating functions to calculate accurate costs for a non-stocked made-in item, thereby enabling the computation of profitable pricing for quotes
SYSPRO's Costing per Warehouse feature gives you the option of using different costing methods per warehouse where the nature of the items held may require different methods of valuation for accuracy. For example, you may manufacture as well as distribute a product and therefore wish to apply standard costing to your work-in-progress and average costing to your distribution warehouse; or you may stock high-value, low-usage raw materials which require last or FIFO costing for valuation accuracy.
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.
SYSPRO's custom forms provides a mechanism of adding additional fields to certain master tables and transactions through the master file take-on and transaction programs. These fields can be defined as alphanumeric, numeric or date format. Defaults can be set and fields can be set as mandatory. Once custom form fields have been created and assigned to the applicable programs, operators can view and populate these fields with data . Custom form fields can be embedded in SYSPRO queries and other display forms, which alleviates the need to call up an additional program to view them.
SYSPRO enables you to easily track your customer delivery performance at sales order line level, by enabling the capture of customer request dates. These dates can then be compared to the actual date that the goods were shipped, along with the quantities requested and shipped.
In SYSPRO, you can search, view and report on the details of past customer orders for repeat order, cross- and up-sell opportunities, as well as to gain accurate information for service and maintenance calls.
Within SYSPRO, a customer stock code is an item which you and your customer refer to using different naming conventions. Using the customer/stock code interchange system, you can create a cross-reference linking the two. This enables your customer to place orders using their naming convention, with the system automatically extracting your code and displaying both at the time the order is captured. You also have the option of printing one or both codes on any user-defined sales documentation.
Dangerous goods text can be defined against a stock item to provide information on how to handle potentially dangerous stock codes and can optionally automatically be inserted as comment lines when capturing Sales and Purchase orders
Demand Planning in SYSPRO is done through the Inventory Optimizer (IO) suite of modules which support and enhance strategic decision-making processes in the critical operational areas of supply chain, inventory management and inventory optimization.
Designed to give decision-makers extended visibility and absolute clarity into actual market demand for products and services, SYSPRO IO helps planners in sales, marketing, production and logistics to continually monitor, manage and optimize their strategies. It provides the statistical information and analysis they need to make informed decisions, such as what to make, what to buy, from whom to buy, how much inventory to carry, where to stock and how much.
SYSPRO IO provides statistical information on which businesses can base decisions for managing customer demand. With the real-time perspective provided, planners can accurately evaluate and distinguish between expected and abnormal demand. Planners can easily perform 'what if' scenarios to determine the outcomes of all possible choices without jeopardizing forecast orders.
SYSPRO IO provides planners with the ability to manage related stock items as strategic business units, by applying relationship-oriented techniques to individual stock items. This enables planners to apply powerful aggregated forecasting and planning techniques to obtain maximum breadth of perspective with any number of composite views. By managing inventory in family hierarchies, businesses can improve productivity and customer service levels. The three integrated modules within the suite include:
- Forecasting, provides the baseline, statistical information planners need for decision-making. It uses a combination of historical information, quantitative and qualitative variables, and algorithms to derive accurate demand forecasts. A Pareto Analysis provides insight into the usage and importance of items, based on quantities sold/requested, profitability, cost and price
- Families and Groupings provides further classification, analysis and forecasting above the stock item level. It enables the configuration of product relationships for added business perspective and is ideal in situations where the number of Stock Keeping Units makes the forecasting of individual items unmanageable, or where the collective forecasting of items makes more sense.
- Inventory Optimization provides the practical implementation of inventory management and optimization policies. It helps to determine the optimum levels required for safety stock, seasonal stock, and basic stock, by factoring in considerations such as depletion rate, target service-level, standard demand deviation, order lead time and lead time variability.
Inventory Optimization provides the practical implementation of inventory management and optimization policies. It helps to determine the optimum levels required for safety stock, seasonal stock, and basic stock, by factoring in considerations such as depletion rate, target service-level, standard demand deviation, order lead time and lead time variability.
SYSPRO has numerous discounts within the system; these include terms discounts (offered to those customers who pay their invoices within a specified time period) and sales discounts. Invoice discount codes can be defined with up to three chained discount percentages and the price that must be used to calculate the discount.
Against a customer you can specify which of these discount codes to use against each sales order entry line and which to use for the total invoice amount. The discounts defined here can be used when a stock item's pricing method is set to discounted if the simple or extended pricing method is used. If the inventory item has a pricing method of Discounted, then the system applies the line discount as part of the price and not as an additional discount.
Alternatively you can enter a manual line discount on a sales order line by selecting Discount when you add a line in the Order Entry program. The system will prompt you to enter up to three chained discount percentages, a total discount value, or a unit discount value. When the order is complete, the order discount will be applied.
Another discount method that can be used is the order discount break which can be applied on either the sales order line or the whole invoice, as an alternative way of extending discounts to a customer.
The percentage discount breaks enable you to vary your price according to the quantity or value of items in the sales order. A maximum of 30 discount breaks can be defined for each type of discount selected.
Settlement discounts can be assigned to a customer which must be applied when that customer makes a payment within a specified time period.
SYSPRO's Dispatch Note System allows you to make multiple deliveries against a sales order, enabling the reduction of stock without the need to produce an invoice after each delivery. A dispatch note review program facilitates the easy selection of sales order lines for dispatch.
The Dispatch Note Consolidation program allows you to assemble a series of dispatch notes for consolidation into a single invoice, based on customer or order.
Distribution requirements planning (DRP) in SYSPRO is designed to optimize the movement of inventory in a multi-warehouse environment so that demands can be met effectively and efficiently without relying on excessive stock holdings.
Companies that would typically use DRP include those in the wholesale or manufacturing sectors which have regional demand fed by one or more supply warehouses or manufacturing plants. DRP provides the drivers that enable the Requirements Planning module to suggest Supply Chain Transfers from one warehouse to another rather than a purchase order on an external supplier or a job on production. Suggestions are based on the closest warehouse in a chain of supplying warehouses, resulting in stock being supplied from oversupplied warehouses to those with a demand.
The integration between SYSPRO's Inventory, Purchase Orders, Sales Orders, Bills of Materials, Work in Progress and Requirements Planning modules provides a comprehensive view up and down the supply chain.
In SYSPRO, dock-to-stock enables you to indicate the number of days after the item has been delivered before it can be sold or used. It can also be used to build in safety lead time for unreliable suppliers of purchased items. The dock-to-stock of items used in the manufacture of other items is incorporated into the cumulative lead time of the higher level items.
SYSPRO provides you with the capability to harness e-Commerce opportunities and thus increases the potential to transform your business and enhance commercial success and growth. It facilitates streamlined, secure electronic data interchange and collaborative commerce through features such Document Flow Manager, e.net Solutions, EDI, Office Automation and Messaging, SYSPRO Workflow Services and various Business-to-Business purchase and sales import and export functions. In addition, SYSPRO's Web applications are out-the-box solutions which you can run on the Internet/Intranet and easily customize to suit end-user requirements.
SYSPRO continues to pursue its long-term strategy of delivering cutting-edge enterprise software and unlocking value by providing the latest technology foundation to our customers. Customers can in turn extend beyond their enterprises by embracing these technologies and SYSPRO's open interface.
SYSPRO's comprehensive distribution capabilities are further enhanced through Internet buy and sell side-solutions. SYSPRO e.net Solutions provide your customers with access to information, order visibility, online self-services and enhanced communications. At the same time they enable you to take advantage of purchase orders, production schedules and electronic procurement using supplier catalogues.
Within the Engineering Change Control (ECC) module, engineering change orders (ECO) function as the central mechanism around which changes to your bills of material are controlled and tracked, and status-related events are triggered.
The Engineering Change Order process is a workflow type subsystem. If a product is under the control of ECC, then any maintenance to a bill of material and/or routing of the product can be accomplished only by means of a current ECO.
Engineering Change Orders provides the mechanism to:
- assign product design tasks to particular users (or groups of users)
- transfer tasks between users (or groups of users)
- notify users of new tasks
- remind users of outstanding tasks
- sign off engineering changes electronically
Where products cannot be reduced back to their original state once in process, the cost of inaccuracy in design and production is high. SYSPRO enables you to implement continuous improvement by helping you to identify problems and points of waste as they happen. Our solution facilitates the tracking of materials from purchase through production to customer, thereby maximizing quality control and providing you with the tools to manage product recalls, should they occur.
- Our workflow management solution applied during the product design process assists by ensuring the new and redesigned products pass through the relevant testing and approval processes before release.
- SYSPRO provides flexible definitions for raw material requirements as well as for the configuration and tracking of quality inspection points and metrics, to help ensure product quality and high production yields.
- SYSPRO enables you to flag purchased items as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns is recorded.
- SYSPRO also provides various operation run time methods, as well as material and progressive scrap functionality. The capture of various lead time elements enables accurate calculations of manufacturing and cumulative lead times, which in turn aid efficient materials planning and production scheduling, as well as product costing.
Job cost accuracy is essential in attaining correct pricing and profitability, as well as to assess the reliability of the quoting process. SYSPRO's Estimating functionality enables the specification of materials, labor and overheads involved in carrying out the specified work, thereby providing a complete view of costs and lead time for job shop or project-based work. Additionally, its' what-if capabilities enable you to quickly model the cost and lead-time impacts of using alternatives, such as different suppliers, routings and materials.
Necessary to meet statutory reporting requirements when fluctuating exchange rates result in inaccurate statements of various financial balances, the revaluation of foreign currency transactions is available for transactions in accounts payable, accounts receivable, cash book and general ledger.
For accounts payable and accounts receivable, the revaluation will calculate and optionally update the local equivalent of outstanding foreign currency invoices, debit notes and credit notes. For cash book, it will revalue unreconciled foreign transactions and foreign bank balances using the current exchange rate and update the relevant ledger accounts with the difference. The cash book revaluation features also enable you to report on the gains or losses associated with fluctuating local values of outstanding foreign transactions and bank balances resulting from fluctuating exchange rates.
Within the general ledger, you can revalue any of the alternate currency ledgers based on the revaluation categories which you have assigned to the general ledger codes. The revaluation category defines the revaluation method applicable to each alternate currency in use, as well as the gains or loss ledger account defined for variances arising from the revaluation process. You can choose to revalue opening balance and movement, or movement only for the current period using an average rate or the month end rate. Triangulated rates are catered for as well.
Typically, the basis of a job's expected costs is derived from the materials and operations defined against the bill of material (or estimate, in the case of quotations); however, changes are often made to these allocations after the job is created, but before work actually commences. In some cases, these changes affect the expected costs of the job.
For example: when your vehicle is serviced, a standard bill of materials and routing is probably used to create the job. Any additional work you request could result in additional material and time, which is added to the job and you would probably want to recalculate the expected costs.
SYSPRO's Job Cost Recalculation program facilitates this, thereby enabling a more realistic comparison. You can choose to report on the changes only or update the job with the new expected costs.
If the job is part of a bill of jobs, SYSPRO rolls up the new expected cost for the sub jobs to the master.
SYSPRO provides for manual, semi-automated or fully automated posting of production data, and for standard or actual quantities and time. Specific issue, kit issue and back flushing features allow for manual and semi-automated processing, while SYSPRO e.net Solutions facilitates secure integration to best-of-breed shop floor control systems for fully automated posting of production data.
SYSPRO's Forecasting enables the entry of manual forecasts, as well as the automatic generation of forecasts via a variety of forecast algorithms, including those that compute for trends, seasonality and cyclical events. In addition, the module provides a competition forecasting method (also known as focus forecasting or the tournament method) which attempts to select the most suitable forecast algorithm based on a selected error measurement and your recent SYSPRO sales history data. This enables you to compare results to determine which method is the most suitable for any particular item, whether you forecast on products at code, revision, release, or warehouse level.
A tracking signal is used to indicate when the validity of the forecast might be in doubt; those items with high forecast errors are highlighted and can be reviewed and adjusted as required.
Companies importing and exporting goods and services would typically make use of SYSPRO's Foreign Currency facilities as foreign currency transactions are created throughout the procurement and sales processes in SYSPRO, where the currency of the Customer or Supplier is different from the local currency of the Company. For General Ledger purposes the foreign currency transactions are automatically converted into the Company's local currency and optionally, into other foreign currencies based on either the current or a fixed exchange rate. Foreign currency transactions may be revalued in the Accounts Payable, Accounts Receivable, Cash Book and General Ledger modules when required.
The system provides full visibility of all foreign currency transactions, together with their local equivalent.
General Ledger analysis provides a means of distributing transaction values to ledger accounts together with analysis information. This reduces the need to create individual ledger accounts for certain categories of expenses, such as traveling, repairs and maintenance, donations and general expenses. It also eliminates the need to manually analyze such general ledger accounts.
SYSPRO's Goods in Transit system comprises the policies, processes and controls used to manage the movement of inventory between warehouses. It allows you to reserve stock for transfer at a later stage, produce documentation for the physical stock movement and to receive the stock at the end. There is a facility to include a cost multiplier (i.e. an extra cost for the receiving warehouse to compensate for the actual transport cost).
If a company is using multiple warehouses and is regularly transferring stock between these warehouses, then the GIT system is highly recommended. Along with documentation, in-depth reporting and comprehensive security, it allows a company to carefully manage and control their stock movement between multiple warehouses.
The Graphical Planning Board is a basic finite capacity scheduler which enables manual manipulation of the schedule via a graphical Gantt chart view and provides limited rules and features for automatic scheduling. It schedules using basic forward and backward scheduling algorithms and considers only the main resource (machine) required for an operation as a constraint. It is ideal for smaller manufacturing companies that need to schedule a small number of production jobs at any point in time, or those manufacturing companies who have only basic scheduling requirements.
The GRN Suspense system enables you to electronically reconcile delivery values with supplier invoice values, raise accruals within the correct financial period and track cost and purchase price variances. This enables you to keep tight control over your purchasing costs for raw materials and other goods and services and ensure that you are paying only for what was authorized and actually delivered.
Hierarchical jobs enable the estimating, recording, costing and tracking of project-based transactions to the relevant project deliverable or section. SYSPRO provides the tools for you to compare, at a glance, actual versus expected material, labor, and fixed and variable overhead costs for each section of a project, as well as committed and uncommitted costs, and projected and realized profits. This enables you to easily identify and investigate cost variances as they occur, as well as profitable and non-profitable areas of project work.
Hierarchical jobs enable the estimating, recording, costing and tracking of project-based transactions to the relevant project section. This facilitates the analysis of expected and actual costs, revenues, billings and profit in measurable user-defined deliverables, as well as the linking of labor tasks and material requirements to the relevant section. In this way SYSPRO assists you in tracking the progress of the different sections of project work against budget; which in turn helps you to identify cost overruns as they occur, as well as unplanned changes in scope that may require the raising of variation orders.
SYSPRO gives you the tools to help you forecast future demand, based on seasonal, cyclical and trend demand patterns in your sales history and lost-sales data. This enables you to plan your production and purchasing to meet these requirements.
- SYSPRO's Forecasting solution gives you the tools to plan your production and purchasing to meet future demand.
- A powerful Pareto analysis feature enables you to easily identify fast, slow and obsolete items in terms of sales value, gross profit, cost of sales, quantities sold or hits, so you can make decisions about which items to forecast, and the best method to use for each.
- You can choose to create forecasts at stock code/warehouse level, and with SYSPRO Families and Grouping you can aggregate your forecasts into user-defined groupings. A variety of forecast calculation methods are also available in Families and groupings including the competition method, as well as the facility to track the forecast quality.
- Additionally, you can select to manually forecast items which require market intelligence, while selecting to batch forecast all other items, and filters and adjustments can be applied to sales history to account for outliers and other abnormalities.
- Multi-level analysis of product performance is available, including at stock code, warehouse, product class, supplier, planner and buyer levels, as well as at user-defined group level if the Families and Groupings module is installed.
- The approved forecast becomes the demand input to SYSPRO's Material Requirements Planning system. This gives your planners and buyers visibility to the resources and actions required to meet the demand in the short, medium and long term.
While forecasting is, by definition, an inexact science, its purpose is to improve the quality of predictions and thereby enable the fine-tuning of the balance between supply and demand. Improved forecast accuracy is essential to minimize inventory holding and obsolescence costs, particularly in forecasting environments where product ranges and configurations are extensive, bills of material complex and raw material and component lead times long.
- SYSPRO provides the inventory management tools to enable you to track and evaluate your forecasts, as well as to identify the possible causes of forecast errors. These tools assist in optimizing your forecasts to produce the best possible outcome with minimum forecast error.
- SYSPRO Inventory Optimization enables the entry of manual forecasts, as well as the automatic generation of forecasts, including those that compute for trends, seasonality and cyclical events. In addition, the module provides a competition forecasting method (also known as focus forecasting or the tournament method) which attempts to select the most suitable forecast algorithm to enable you to compare results to determine which method is the most suitable for any particular item.
- Forecast accuracy depends not only on the regular evaluation of the forecast error, but also on the integrity and nature of the source data. In SYSPRO forecast accuracy is enhanced through the ability to automatically filter and adjust outliers, as well as to manually adjust forecast base data for quantitative and qualitative factors.
You can flag purchased items as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns is recorded. Units in inspection are visible, but unavailable for use until accepted into stock. Similarly, work in progress inspection gives you the tools to inspect manufactured product quality and, depending on the results, select to receipt, scrap or rework quantities. You can receipt inspection items as the original product to manufacture, or as a different product or products, which is useful for end-products of variable grade. Also, you can receipt items into a warehouse different from what was originally planned.
The interactive graphical planning board features of SYSPRO's Factory Scheduling are geared towards providing schedulers with complete visual control over scheduling activities. This is achieved via Gantt charts and other visual representations of production resources, load and schedules which, in addition to the more sophisticated automated scheduling and sequencing features, provide the capability for rapid manual manipulation of operations via drag-and-drop editing.
As well as providing at-a-glance views of information such as job lists, unscheduled operations, schedule dates, and the automatic display of any job or operation that is late, the graphical display provides rapid identification of additional operation and resource statuses through its powerful locator and highlight facilities. Both deliver the capability to find and work with targeted information in isolation; for example, finding and re-scheduling all operations for a high priority order or customer, or re-scheduling all operations with sequence errors.
The Boolean search provides the means to find jobs and operations based on criteria, such as customer, planner and work center, while the highlighting functionality is utilized to locate operations in specific states such as locked, started, early, late, and delayed, as well as bottleneck operations and those with sequence errors. Furthermore, the highlighting feature can be used to reveal a trace on the Gantt chart between operations for the same job. Detailed tooltips in the Gantt chart provide further operation scheduling information, such as start and end dates, while drill-down access provides further operation detail such as machine and customer. One-click access is provided to resource performance metrics including percentage setup, working and idle time, and a hot-spot grid gives the scheduler a quick overview of machine activity and utilization for different days across a specified time span.
Useful for companies where different schedulers are responsible for scheduling different areas of production, SYSPRO enables the definition of multiple user-defined screen layouts, as well as the grouping of the Gantt chart display by work center or resource; configurable icons provide one-click access to user-defined layouts. Extensive user-configurable display features include color coding or patterning by stock code, product class and operation elements; as well as resource states, and job and operation statuses. User-configured icons aid visual differentiation of products on the schedule.
The graphical planning board facilitates the saving of multiple workspaces (schedules) for what-if comparisons, as well as the publishing of charts and schedules for viewing by other company members regardless of whether they have SYSPRO installed.
SYSPRO Inventory Optimizer provides visibility into the status of all forms of inventory across the inventory flow cycle. Quantities of raw materials, work-in-process and finished goods inventories are automatically updated and forecasts adjusted in accordance with the organization's inventory management and optimization policies. This gives planners enhanced capability to manage demand fluctuations and buyers, the tools for efficient purchase planning.
Full visibility is provided of all stock levels per warehouse, such as quantity-on-hand, on- order (PO and WIP), available, allocated to sales orders, on backorder, allocated to WIP, in-transit, in-inspection, and future free. An available-to-promise query can be performed at any location in the system to establish what stock is available or when stock will become available.
This provides the tools for you to compare, at a glance, the actual costs for a job against the expected costs, thereby enabling you to identify and investigate cost variances as they occur. For a job for a made-in product, the basis of the expected costs is derived from the materials and operations defined against the bill of material (or estimate, in the case of quotations). Work in Progress queries and reports enable you to view the comparisons at job (labor and material totals), material allocation and labor allocation level. The Job Cost Recalculation program allows you to recalculate the job expected cost totals for labor and material, if you add allocations after the job has been created, thereby providing a more realistic comparison.
Through its structured design and capability to copy from existing jobs, the Jobs function in SYSPRO enables the rapid entry of production orders for the manufacture of both standard and non-standard products, as well as for service and project jobs.
Central to the Work in Progress module, its integrated nature simplifies the creation of jobs by facilitating the automatic creation of materials and internal and subcontract labour allocations from bills of materials and estimates, as well as from product configurations formulated using SYSPRO's Product Configurator. Furthermore, it simplifies the entry of non-standard allocations for ETO, MTO and project manufacturing environments and enables the rapid creation of bills of jobs.
Below is a listing of all the Key Features and Functions available in SYSPRO's ERP Solution. A great way to review these is to hover you mouse over the main "Industries" link at the top of the page and select the industry appropriate to you. On the left hand side of the page you will see a list of Key Features and Functions that are applicable to your industry.
You use the Job Issues function to record the issue of items from inventory for a specific job. The quantity entered is subtracted from the quantity on hand and costed at the current inventory cost. The unit cost differs from one warehouse to another. The materials of a kit issue and a specific issue is costed in the same manner. When you do a kit issue you can specify labor costs. These labor costs are added to the material costs to determine the total cost of a job. The total cost can be divided by the quantity to make, which gives the unit price of the manufactured item. Labor is calculated as the hours worked multiplied by the work center rate and reflects the actual hours worked per job.
The Single Level Bill of Materials in Sales Order entry provides the facility to sell items in a Kit form with specified mandatory and optional components. Companies in the wholesale or assemble to order manufacturing sectors and who sell items in kit form would typically use the Single Level Bill of Materials facility.
The Bill of Materials module is required to define relationship between the finished (parent) part and the components so as to determine the cost and selling prices and whether the stocking levels of the parent or the component are affected.
Labor posting allows for time to be posted against a specific job. Each labor entry increases the labor costs to date and the number of hours booked against the job.
Lead time calculation calculates the cumulative and manufacturing lead times of an item and updates the relevant fields against the stock item.
Particularly useful in a make-to-order environment, the ability to create linked sales orders, purchase orders and jobs in SYSPRO provides a quick and simple way of raising and linking those transactions required to fulfill a customer order.
If using the Quotations module, you can quickly raise the customer order and the supplying jobs and/or purchase orders from a single point of entry when confirming the quote. If the Quotations module is not in use, the planning and purchasing departments can easily raise the necessary build and purchasing orders via SYSPRO's various review or trial kitting facilities once the customer sales order has been entered. Optionally, sales order staff can be given the necessary access to raise the jobs at the time of entering the customer order. The link between customer order, manufacturing and procurement provides visibility and enables progress tracking throughout the life of the order.
SYSPRO's load planning is particularly useful for companies who either use their own delivery vehicles but do not require a full tracking and load-balancing system, or who outsource their deliveries but need an efficient way of preparing and optimizing their loads.
It provides a framework for improving the planning and management of customer order delivery schedules. It assists in determining when orders can be delivered, as well as improving the processes around the actual picking and loading of goods for subsequent delivery.
SYSPRO's multi-level bill of materials functionality enables the definition of complex production recipes whilst control over recipe changes is seamlessly handled by the Engineering Change Control (ECC) module. A where-used query and substitution facility enables quick and easy replacement of ingredients and the relationship validation function enables you to easily identify illogical relationships within your bills.
- For each bill level, you can define ingredient quantities such as quantity per, fixed quantities or wet weight percentages in relation to that specific level’s parent item. Component and operation copy, insertion, and move facilities enable straightforward maintenance of new and existing bills.
- The Work in Progress module enables seamless ingredient substitution where actual ingredients differ from planned. Furthermore, where intermediate or finished products differ from planned, the Work in Progress inspection functionality enables receipting of these products as alternate warehouses or bins.
- SYSPRO's multimedia functionality enables you to attach visual and textual material, such as videos, photographs, and certificates of conformance, to structures and operations.
- Custom forms enable you to create additional user-defined fields. Phantom bills accommodate transient production items, and planning bill functionality aids option forecasting and planning. In addition, the configuration and manufacture of multiple items which are produced in a single process are accommodated by SYSPRO's co- and by-product features.
SYSPRO enables the time-phased planning and execution of both dependent and independent component replenishment, as well as the efficient management of component issues to production. Our solutions ensure that automatic replenishment calculations for dependent demand satisfy quantity and date requirements, as well as catering for independent demand for spares. We also have the tools to cater for other replenishment-planning approaches which may be better suited to optimizing inventory in your environment.
- The system's component-to-operation linking facility, on both standard and non-standard product bills of material, as well as its order policy, lot sizing and dynamic lead time functionality, ensures that automatic replenishment calculations for dependent demand satisfy quantity and date requirements. Independent demand for spares is also catered for through the use of SYSPRO's multi-level MPS and forecasting functionality. Inventory order-point indicators, such as reorder point, minimum/maximum levels and safety stock, provide the tools for other replenishment-planning approaches which may be better suited to optimizing inventory in your environment.
- SYSPRO enables the quick review and execution of suggested actions for component purchasing and production, using either the Requirements Calculation or trial kitting criteria as a source. For make-to-order and engineer-to-order environments, sales order-to-job linking, purchase order- to-job linking and the bill-of-jobs features enable the automatic raising and linking of component requirements for a customer order line. Extensive purchase order and blanket purchase order functionality, as well as SYSPRO's electronic collaboration tools ensure fast and secure communication of orders to suppliers around the globe.
- SYSPRO's Multi-level Trial Kitting program enables you to quickly check that you have all components required for a standard part, job or bill of jobs before issuing any materials or launching a job onto production and if not, where shortages exist. The Kit Issues program determines the exact issues required for a user-defined range of job operations, thereby helping to avoid cluttering the production area with unnecessary component inventory.
- Where production runs are short and work-in-progress control is not required, SYSPRO's back-flushing enables you to issue components used, on receipt of the parent product.
- SYSPRO's where-used query and replace facilities enable seamless replacement of one component with another throughout relevant bills of material, while the Engineering Change Control (ECC) module enables full version and release level management of this process if required.
SYSPRO's efficient Contact Management functionality enables the centralized maintenance of all contact information and associated activity. This enables organizations to keep track of their associates and tasks; and provides salespeople, customer service representatives, and managers with a central, up-to-date view of business contacts.
Procurement management SYSPRO's Requisition System streamlines procurement management by enabling the implementation of an electronic workflow for your purchase requisitioning and approval processes, along with optional Capex monitoring.
SYSPRO's Inventory Management solutions enable the definition of multiple user-defined units of measure (UOM) for stocked items: Stocking UOM, Alternate UOM, Other UOM and Manufacturing UOM. These units of measure, along with their conversion factors, are used in various parts of the system to ensure accurate quantities for sales, purchasing and production.
For production purposes, SYSPRO’s multi-level bill of materials functionality enables you to define the manufacturing recipes and methods for bulk, intermediate and pack items. For each level in a multi-level bill, you can define ingredient quantities as quantity per, fixed quantity or wet weight percentage in relation to the UOM defined for that level’s parent item and routing.
Having the capability to create and execute an achievable schedule requires a comprehensive view of the current situation and available resources, as well as the tools to perform efficient re-scheduling if necessary. SYSPRO’s visual scheduling products provide this capability to suit all levels of sophistication and complexity, from basic manual drag and drop to automatic algorithm-driven scheduling and changeover optimization.
- Whether you operate a simple scheduling environment requiring single-constraint finite scheduling, or a complex environment requiring multi-constraint and rules based finite scheduling, SYSPRO can help you optimize your scheduling activities with its Graphical Planning Board, Factory Scheduler or Advanced Scheduler.
- For batch process environments, SYSPRO Factory Scheduling provides the planner with an interactive decision support tool that helps balance demand and resource availability. Optimization is enhanced through the consideration of priorities, constraints and conflicts, as well as sequencing and synchronization requirements.
- Automatic forward, backward and bi-directional scheduling is available, along with manual intervention. The customizable graphical interface enables quick and easy identification of schedule loads, job and operation statuses and links, and resource availability. One-click schedule performance metrics, as well as the ability to run, save and compare schedules, provide what-if capability and enable the scheduler to choose the best option for the current circumstances.
- On-the-fly extraction of work-to-lists and other reports is via standard reports, as well as the user-friendly report writer, while features such as emailing and web publishing of information enable the current schedule and metrics to be viewed by all stakeholders.
The traceability of products from material origins through manufacture to final destination is a key system requirement in many industries whether compliance-critical, or an analysis tool for continuous improvement strategies. SYSPRO facilitates the recording of traceability and quality data on materials and products from purchasing through inspection, manufacturing, manufacturing inspection, stocking and sales. The recording of expiry and shelf-life information is also facilitated, and powerful queries enable both upward and downward searches by stock code, lot number and transaction type.
- SYSPRO’s integrated nature enables full backward and forward traceability, as well as comprehensive recordkeeping to meet strict compliance requirements. Shelf life management is facilitated through expiry dates, and you can use SYSPRO’s customization and custom form features to record other compliance-code dates, as well as to capture storage and transport compatibility codes.
- SYSPRO’s lot traceability and serial tracking functionality afford full visibility to the origins, build and customer destination of products and batches, thereby providing the means to rapidly trace and analyze the source of defects should they occur.
- SYSPRO’s Engineering Change Control (ECC) module enables complete management and traceability of changes to product designs, while the Return Merchandise Authority provides consistent handling of product returns, as well as analysis data for improvement programs.
Strict management of raw material lead times is vitally important in controlling overall procurement costs and attaining customer service level targets. SYSPRO enables you to monitor quoted purchasing lead times against actual supplier delivery performance and to flag reliable suppliers of specific raw materials as certified in the system, as well as to track blanket purchase order contracts.
Component-to-operation linking and component offsets facilitate the implementation of JIT and LEAN purchasing principles for raw materials. In addition, inventory order point indicators, such as reorder point, minimum/maximum levels and safety stock provide the tools to help you mitigate problems associated with unreliable supply of long-lead time items.
Efficient management of the processes involved is essential to the success of new product launches.
- SYSPRO provides tools to streamline and track the introduction of new product designs and amendments to existing designs, along with relevant costings. A built-in workflow engine - SYSPRO Workflow Services (SWS) - enables you to streamline and manage the integration and execution of the entire design-to-market process, including the relevant activities that fall outside the SYSPRO system.
- Engineering Change Control (ECC) enables you to apply strict control over your product design activities 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.
- SYSPRO’s inventory management solutions such as Families and Groupings and Forecasting enable the entry of manual forecasts, as well as the automatic generation of forecasts - combinations of forecasts and other sources of demand, such as sales orders, can be configured as the demand drivers for new products in Requirements Planning.
- The Contact Management system facilitates the marketing of new products to your customer base, while the Trade Promotion features help to streamline the processing and management of the trade promotions that are routinely offered on new products.
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.
You can define and process both manufactured parent and component quantities in a unit of measure other than stocking. Unit costs, quantities, values, run time and time taken (where applicable) are displayed and printed according to the relevant unit of measure selected.
Material and labor allocations provide expected quantity and values against which to measure actuals for a job and the labor allocations are used to calculate the start and finish dates of a job. If a job is created from a bill of material or a quotation, the allocations will automatically be created from the bill or estimate. Alternatively, they can be entered manually against an existing job.
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.
Selected Case Studies:Bernina RSA
Daikin Air Conditioning SA
AJ Wells and Sons
Ernest H Hill
In SYSPRO, you can set up minimum and maximum stock levels, per stock code per warehouse, to assist with replenishment planning. Using SYSPRO's Warehouse Exception report, you can select to print those items that have fallen below minimum or exceeded maximum. In addition, using SYSPRO's Office Automation and Messaging module, you can configure an event that will inform the relevant operators via mechanisms, such as email, when the minimum/maximum levels are breached. You can also choose to base a stock item's warehouse order policy on its minimum/maximum levels, which means that these levels will be taken into account if you use SYSPRO's Requirements Calculation to generate your material requirements.
Raw materials and manufactured products often vary in grade and quality, so, for many industries, tracking and control is essential to reduce waste, scrap and defects. SYSPRO enables you to implement continuous improvement by helping you to identify problems and points of waste as they happen.
- SYSPRO queries and reports functionality enable you to specify approved manufacturers for raw material supplies, and easily track supplier performance. In addition, SYSPRO facilitates the tracking of materials from purchase through production to customer, thereby maximizing quality control and providing you with the tools to manage product recalls, should they occur.
- You can flag purchased items as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns is recorded. Units in inspection are visible, but unavailable for use until accepted into stock. Similarly, SYSPRO Work in Progress inspection gives you the tools to inspect manufactured product quality and, depending on the results, select to receipt, scrap or rework quantities.
Throughout SYSPRO transactions can be processed and viewed in both local and foreign currencies and are transferred into local currency before being processed into the General Ledger. Exchange rates can be fixed or established at the time of transaction processing.
The General Ledger system allows for up to 10 alternate reporting currencies which are converted from the base/local currency using a historical exchange rates table.
The Accounts Receivable sub-ledger allows for transactions, such as invoices, credit notes and payments, to be processed, viewed and reported in both local and foreign currencies. It provides you with the flexibility to either establish a fixed exchange rate against receivables transactions, or use the current rate from the system's global exchange rate table. You can revalue outstanding unfixed-rate invoices for statutory reporting requirements, when fluctuating rates result in inaccurate outstanding receivables values.
Multi-Level Trial Kitting provides an alternative to Material Requirements Planning and is an attempt to emulate the manual method used by build-to-order companies to build a finished item: the drawing office provides a list of components for each sub-assembly and component and the Kardex information is used to determine which jobs and purchase orders must be raised, taking into account the stock on hand.
It enables you to establish which jobs need to be raised through several levels of a structure as well as the purchasing requirements required to complete the build. All sub-assemblies and components are processed, multiplying the quantity per by the net requirement of the parent. This is then compared to the net quantities on hand to determine the shortages.
Within SYSPRO, you use multiple warehouses to record stock holdings stored at multiple physical or virtual locations. Stock transactions and various quantity type summaries, such as on hand, on order and on backorder are stored per warehouse. In addition, costs, buying rules, minimum, maximum, safety, re-order and pallet quantities are held per warehouse.
With visibility of inventory across multiple locations, inventory managers, planners and purchasers have the information to rationalize and optimize inventory levels and sales staff and customers can easily determine product availability.
The multimedia facility enables you to integrate images, documents, and sound and video clips with key data and processes; for example, you can attach a drawing to the manufactured part's stock code, as well as video clips to the bill of material operations to provide visual explanations of the manufacturing processes required.
SYSPRO's multiple bins feature enhances the efficiency of warehouse management by enabling the recording of the precise location in a warehouse, such as rack and level number, of any stock item. Additionally, you can choose the specific warehouses in which to implement this feature so as to reduce processing time for those warehouses where it is not required
Because a company does not necessarily need to record the precise location of all its stock items, a multiple bins by warehouse facility enables you to specify that only certain warehouses require a binning process. This can reduce the time taken to receive and sell goods from other warehouses.
Throughout SYSPRO, standard free-format notes can be entered against master data and transactions for display in queries, as well as for printing on various documentation and reports. In addition, you can insert an editable or read-only notepad against any key field using SYSPRO's powerful customization facilities.
SYSPRO's on-line master production scheduling (MPS) feature provides the production planner with the tools to schedule the production of independent demand items, taking into account current and future demands, as well as existing production and safety stock. Based on these factors, as well the MPS item's gross requirements rule and order policy, the system calculates suggested build schedules, which the production planner can review and confirm on-line.
Part billings allows you to invoice a customer based on work completed for a non-stocked job. At the same time the work in progress value is reduced and can be distributed to General Ledger codes of your choice.
A planning bill is an artificial grouping of items and/or events in bill of material format that is used to facilitate master scheduling and/or material planning. It is sometimes referred to as a pseudo-bill of material.
It cannot be stocked, sold or bought and is used to forecast a family of products as one entry, while generating gross requirements into the master production schedule (MPS) or material requirements planning (MRP) for each member of the family independently.
Planning bills provide an aggregate forecast tool for forecasting families of products with a similar sales profile. It allows you to make decisions about your items, ensuring that you have right amount of materials and resources available to make the required item.
SYSPRO enables you to view and optionally update global increases or decreases to either the selling price or the inventory cost of your stock items, based on various selection criteria such as stock code, warehouse, supplier and product class. The Price Cost Percentage Change feature provides a fast method of effecting price changes by a percentage, a percentage based on cost, or a percentage based on an existing price code. You can make changes to existing price codes, or create entirely new price codes if, for example, you are creating new customer buying groups. The feature also facilitates rapid implementation of global cost changes by a percentage based on existing cost, which is useful in a standard costing environment.
SYSPRO offers both manual and automated pricing. Automated pricing can be based on customer and/or stock code matrices and contract pricing at customer and/or buying group level by product or product group. Discounted, foreign and quantity break pricing methods are catered for, as well as minimum profit margin checking. The import, export and global price update facilities enable seamless implementation of extensive price changes.
Trade Promotions pricing facilities enable the creation of rules that govern pricing, promotions, special offers and rebates.
Procurement planning in SYSPRO assists the buyer by providing end-to-end visibility of the procurement process. From supplier relationship management, to Order monitoring, to suggested forward ordering and changing in order to meet future requirements, to linking component ordering and outside service subcontracting directly to Works Orders and/or Sales Orders.
SYSPRO's Projects and Contracts module enables you to record a deposit from your customer on acceptance of your quotation for project work, as well as the method and schedule of billings for the project invoicing. Additionally, you can record an amount or percentage of the contract value that will be withheld by your customer for a prescribed retention period, enabling you to define the terms of your customer's final payment, as well as the timing of final invoicing on a project.
SYSPRO's progressive scrap utility enables you to easily track scrap at every operation and measure scrap tolerances, thereby facilitating more accurate production costs and lead time calculations. You can also track scrap at material level against components. You can plan for scrap percentages or scrap quantities against operations in a bill of material, and at the time of creating a works order you can optionally select to inflate the material allocations according to the scrap percentages and/or scrap quantities defined against the associated operations. If you use the Requirements Planning module, it caters for progressive scrap at the time of calculating the demand of material allocations for works order.
You can capture and query proof of delivery (POD) information against customer invoices, thereby enabling rapid resolution of invoice queries. At a glance, you can view information such as customer order, sales order and delivery note numbers, while invoice and sales order drill-downs provide access to full transaction details. One-click access to invoice reprint, fax and email functionality is provided, as is the facility to view signed delivery dockets which have been scanned and attached to the invoice via SYSPRO's multimedia tool. You can also capture notes against the POD information.
Purchase order inspection permits predefined inspect-able items to be receipted into an inspection file. The inspection transactions can then be recorded - including quantities accepted, rejected, scrapped and returned to supplier - and the final accepted quantity made available for use.
In SYSPRO, you can optionally flag purchased items (stocked and non-stocked) as requiring inspection, so that they are receipted through a 2-stage process. This enables you to record and track the details of all activities associated with the inspection of these items, including the rejecting or scrapping of quantities of items that fail inspection.
Purchasing lead time represents the time it takes in days (including non-working days) from when you recognize the need to purchase a product, to when it is available in your stores for use. Elements of purchasing lead time include order preparation and release time; supplier lead time; transportation time and receiving; and inspection and put-away time.
When the Material Requirements Calculation recognizes a requirement for a purchased item, it will use the item's purchasing lead time to calculate the purchase order placement date from the item's requirement date. Furthermore, SYSPRO uses the lead time of purchased items to calculate the cumulative lead time of the manufactured items in which it is used.
In environments where materials and product replenishment planning is largely based on demand forecasts, the forecasts must be as accurate as possible so as to minimize the costs associated with inaccuracies, such as redundant stock and poor customer service.
Forecast accuracy depends not only on the regular evaluation of the forecast error, but also on the integrity and nature of the source data. Within SYSPRO, forecast accuracy is enhanced through the ability to automatically filter and adjust outliers, as well as to manually adjust forecast base data for quantitative and qualitative factors. Additionally, reports and queries provide comparisons between actual sales, and suggested, draft and approved forecasts.
- SYSPRO's Forecasting module provides tools to enable you to track and evaluate your forecasts, as well as to identify the possible causes of forecast errors. These tools assist you in optimizing your forecasts to produce the best possible outcome.
- The Forecasting module enables the entry of manual forecasts, as well as the automatic generation of forecasts via a variety of forecast algorithms, including those that compute for trends, seasonality and cyclical events. In addition, the module provides a competition forecasting method (also known as focus forecasting or the tournament method) which attempts to select the most suitable forecast algorithm, based on a selected error measurement and your recent SYSPRO sales history data. This allows you to compare results to determine which method is the most suitable for any particular item, whether you forecast on products at code, revision, release, or warehouse level. A tracking signal is used to indicate when the validity of the forecast might be in doubt; those items with high forecast errors are highlighted and can be reviewed and adjusted as required.
A key way to reduce lead times is by being able to identify and eliminate waste. The integrated nature of our software helps you to do this by giving you complete visibility across the entire supply chain from order taking to delivery, and providing you with the tools to monitor and improve lead time performance. Our software also enables the co-ordination of activities such as analyzing lead time constituents and non-value-add activities.
- SYSPRO's 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 with 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 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.
- 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 thereby facilitating improved utilization of manufacturing resources.
SYSPRO provides the facility to enable you to quickly replace a component stock code with a valid substitute component in those bills of material in which it is used. For items under engineering change control, this includes the selection of which revision and/or release to process. If the component which is being replaced already exists within the structure for the parent stock item, then you can indicate whether you want to accumulate the quantities of the component, or skip the replacement.
Within SYSPRO, order policies refer to the rules that SYSPRO applies when calculating suggested replenishment orders for purchased or manufactured stock items; you use these rules to apply the order policies that your company has formulated.
SYSPRO order policies are extremely flexible and enable you to cater for the possibility that different warehouses in your organization may have different replenishment rules for the same stock code; for example, branch warehouses with different local costing and storage issues. To this end you can configure order policies at warehouse level, specifying such criteria as major and minor order multiples, and minimum and maximum order quantities.
In SYSPRO you can reserve lots for parent parts (before they are receipted into stock) and you can reserve lots for allocations (before they are issued) when a job is confirmed. In addition you can track which component lots were used in the production of a particular parent lot (one-to-one tracking between component lot and parent item lot).
In SYSPRO you can reserve serial numbers for parent parts (before they are receipted into stock) and you can reserve serial numbers for allocations (before they are issued) when a job is confirmed. In addition you can track which component serial numbers were used in the production of a particular parent serial number (one-to-one tracking between component serials and parent item serials).
Giving an operator access to multiple programs might result in a role conflict, if having access to those programs could result in a breach of company security policy, for example being able to post Invoices, as well as being able to post payments in Accounts Payables. A report highlighting operators who have access to programs that result in a role conflicts can be produced.
The safety stock highlights instances where stock falls below a prescribed level, for the Requirements Planning module to suggest ordering. Warehouse exception reporting also allows for reporting on all items where the on-hand stock level has fallen below safety stock
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.
SYSPRO's progressive scrap utility enables you to easily track scrap at every operation and measure scrap tolerances, thereby facilitating more accurate production costs and lead time calculations. Scrap can also be tracked at material level against components. You can plan for scrap percentages or scrap quantities by entering them against bills of material; at the time of creating a works order you can optionally select to inflate the material allocations according to the scrap percentages and/or scrap quantities defined against the associated operations. The Requirements Planning module, caters for progressive scrap at the time of calculating the demand of material allocations for works order. All recorded scrap is stored for reporting and analysis purposes.
Serial tracking is designed to provide full tracking at transactional level for those items that have serial numbers assigned for warranty or compliance purposes. The serial numbers can either be unique per individual item or the same for a batch of items.
Each operation can have a number of different times specified so that the time taken to setup the manufacturing environment, machinery and work centers to perform the operation and time to teardown the environment down can be accurately recorded and accounted for.
The different times include:
- Set-up time indicates the time taken to ready a specific machine, process or work center for use. No usable items are produced during the setup period. It forms part of an operations elapsed time.
- Startup time is used to indicate the time taken to gradually bring the specific machine, line or work center up to full production speed while producing usable product. It forms part of an operations elapsed time.
- Startup quantity is used to indicate the quantity of product manufactured during the start up period and is deducted from the actual quantity to be manufactured when the run time is calculated.
- Teardown time is used to indicate the time taken to close down the specific machine, line, or work center used in the operation after production is complete. It forms part of the elapsed time. Typically, no usable items are produced during the teardown period.
- Wait time is used to indicate the amount of time between the end of the current operation and the availability of the product to be moved to the next work center. This forms part of elapsed time. Wait time is not included in the calculation of capacity required or in the costing calculations.
The Specific Issues function in Work in Progress enables you to post materials to a job for a specific allocation, or for which there are no pre-defined material allocations. This is useful for quickly issuing off materials consumed on non-standard jobs, or negatively receipting materials that have been over-issued in error.
SYSPRO's Statistical Accounting feature facilitates the recording of non-financial information which you can then use to create detailed reports for analysis of financial information. For example, a statistical account can be used to record head count per department to enable the detailed analysis of administration costs by department in a financial report.
The cost of procuring raw materials and components often constitutes a substantial percentage of the total costs of producing a product. To control these costs it is essential to monitor supplier performance in terms of price, quality and on-time delivery. SYSPRO provides a number of reports that enable you to monitor these areas of suppliers' performance at a detail level.
The Supplier Performance report gives you the details of each purchase order receipt including any variance between the original purchase order price and the receipt cost, as well as the age in days between the original line due date and the receipt date. You can also select to print a detailed scrap and reject analysis per supplier.
Supplier/stock code cross-reference creates a record of the last purchase made against the supplier for the stock code/catalog number. Information, such as the average number of days it takes to receive the stock item from the supplier; and the date, quantity, unit of measure, and price when the item was last purchased from the supplier.
Supplier/stock code interchange enables you to maintain a cross-reference between a SYSPRO stock code and a supplier catalogue number, so that either number can be used and printed on a purchase order.
Supply chain transfer (SCT) orders are a special type of sales order which enable you to replenish stock between warehouses at the warehouse cost with an optional cost multiplier They provide full visibility of all transfers, with the associated paperwork required for the transfer. Requirements planning will also suggest Supply Chain Transfers is a demand exists in a warehouse, and a surplus exists in its supplying warehouse.
Synchronizing supply with customer demand is a key requirement to prevent costly line stoppages in assembly plants, particularly for component and material suppliers of original equipment manufacturers (OEM). This involves not only automating order processing and other processes in the supply chain, but also executing production plans using LEAN principles. SYSPRO facilitates the Lean initiative with an extensive ERP system that integrates all business functions and provides visibility across all areas of the enterprise so that informed decisions can be made, information can be shared and effective collaboration is possible.
- SYSPRO Blanket Sales Orders and Releases provides you with the tools to record contracts with your OEM customers and provides you with an accurate means of tracking and reconciling cumulative release quantities and converting them into sales order quantities. The module enables SYSPRO customers to easily update call-off schedules for their OEM clients, as well as reconcile the cumulative position against their OEM contracts.
- Confirmed customer schedules, in turn, become an input for demand planning and, ultimately, production and purchasing requirements linked to the relevant schedule requirement dates. The Requirements Planning and Factory Scheduling modules provide you with the tools to implement LEAN principles, manage the replenishment process, and ensure that you meet your OEM contract service levels.
- Streamlined electronic collaboration with your OEM customers is facilitated through features such as SYSPRO Workflow Services, Document Flow Manager, SYSPRO e.net Solutions, EDI, Office Automation and Messaging, fax, email and various Business-to-Business import and export functions, thus reducing response time, margin for error and penalties associated with disruption to OEM production lines.
SYSPRO's ERP Software gives you peace of mind by providing the following extensive security features:
- Tailored Security Measures – You can configure the system security to be as simple or as finely tuned as your operating environment requires.
- Controlled Access - Standard security features include password control and group and operator maintenance facilities. Administrators can also control access down to certain business processes, companies, modules, menus, and program functions and activities.
- Data Visibility - SYSPRO's ERP Security features give you visibility to transactional data for key codes such as warehouse, banks, salespersons, ledger etc.
- Audit Trails - Master data amendment journals and transactional audit trails provide records of data changes and the users responsible. The job logging facility provides an audit trail of user access and processing activity.
- Electronic Signatures - Enable administrators to secure transactions by authenticating the operator who is performing the transaction. This can be configured to create a summary and detailed log of all transactions.
SYSPRO improves the accuracy and efficiency of the tedious and time-consuming processes traditionally associated with periodic accrual and deduction review activities.
Trade promotion functionality improves the application and tracking of promotion accruals taken during a sale for later redemption, as well as the management of deductions claimed by a customer for a loyalty program or for services which they may provide on your behalf, such as in-store advertising.
The user-friendly review functions provide the details of promotions accrued to a customer and give you the flexibility to either reimburse the customer or offset the accruals against deduction claimed by the customer when paying their invoices. Deduction management provides the option to accept, reject or write-off rebates claimed and the notes and follow-up features enable the tracking of unresolved deductions.
SYSPRO's comprehensive trade promotions functionality provides increased control and efficient management of your promotions thereby reducing time-consuming reconciliations and improving accuracy and profitability. Furthermore, SYSPRO provides clear visibility to Pareto, forecasting, inventory and sales data thereby enabling the quick identification of suitable items for promotion, such as new, rebranded and seasonal items, slow movers or those nearing expiry date.
Trade promotion features enable efficient implementation and management of the many types of trade promotions that are routinely offered, such as temporary price reductions off invoice, accruals for later redemption, special offer and free goods combinations. Promotions can be applied across groups of items based on quantity, mass or volume and for various customer and location groupings. Multiple promotions can be configured to be applied either automatically or by review at order entry or import time.
Particularly for companies in highly regulated industries, the tracking and replacement of defective materials, as well as the efficient management of product recalls are compliance-critical activities.
SYSPRO's traceability features facilitate the tracking of materials through the receiving, manufacturing, assembly, inspection, stocking and final dispatch stages. This comprehensive traceability helps streamline product replacement and recall activities.
SYSPRO's traceability query enables you to view current and archived lot data from a number of different perspectives through quick and efficient searches, thereby helping you to respond promptly when there are quality issues or product recalls. Whether you need to filter data for all customers or jobs to which a particular lot was supplied; or all lots that have been supplied by a particular vendor or job, the query provides the criteria and relevant launching points to assist you.
To identify and reduce waste and inefficiencies in the production process, you need real-time access to accurate material and labor flow data. SYSPRO enables you to easily query the status of your work-in-progress in terms of costs, material and scrap quantities, labor hours and manufactured quantities. In addition, optional lot traceability and serial tracking functionality enables you to identify the jobs to which traceable raw materials have been issued.
- In SYSPRO, the material and labor allocations are created manually for a non-standard job, or automatically for a job created from a bill of material or estimate. In all cases, you can specify whether the materials are required a certain number of days before the job finish date, or at the start of a specific operation.
- SYSPRO trial-kitting mechanisms provide complete visibility to the availability of materials required for jobs. Flexible posting functionality enables you to issue materials and labor to jobs at any time via a number of methods, including specific and kit issues. In addition, SYSPRO e.net Solutions and Job Import functionality enable seamless integration of shop floor data collection systems. Powerful queries and reports provide detailed information on job status and delivery performance information.
The multi-level Trial Kitting program, is designed to check supply and demand only for materials in the Bills of Materials. It will establish which jobs need to be raised through several levels of a structure as well as the purchasing requirements required to complete the build. All sub-assemblies and components are processed, multiplying the quantity per by the net requirement of the parent. This is then compared to the net quantities on hand to determine the shortage.
SYSPRO's variance bills enable you to capture material variability on a lot-for-lot basis, easily adjusting formulas and recipes while ensuring excellent overall quality. This flexibility enables the manufacturer to use materials in the most effective manner, enabling considerable cost savings.
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.
SYSPRO Factory Scheduler assists in improving your organization's flexibility and responsiveness to market demands by providing clear visibility to production alternatives through its what-if scheduling and sequencing capability. It enables the fast simulation and graphical comparison of alternative production schedules, thereby providing clear visibility to all stakeholders of the effects of decisions made during sales and operations planning, and thus helps to improve collaboration and co-operation between these areas. Additionally, the what-if capability enables the scheduler to rapidly determine the best alternative when problems occur with production equipment, or urgent demands arise.
In SYSPRO, you can optionally flag manufactured items (stocked and non-stocked) as requiring inspection, so that they are receipted through a two-stage process. This enables you to record and track the details of all activities associated with the inspection of these items, including the reworking or scrapping of quantities of items that fail inspection. Furthermore, the system provides for receipting of an item into a different warehouse or stock code than was originally planned, which is useful for graded products.
Work-in-progress tracking enables you to track the progress of jobs until completion. Standard reports and queries provide information on complete and outstanding operations; they also highlight where variances are encountered to date between expected and actual material costs and quantities, and expected and actual labor costs and hours.