Key Features and Functions
The routings functionality enables you to define the operations required to manufacture your products, as well as to cost the labor, and fixed and variable overheads incurred in these operations. Tooling, progressive scrap and transfer quantities are all catered for, as is the facility to record detailed manufacturing instructions.
You can define the expected times for the different elements of internal operation time, such as setup, start-up, run, teardown, wait and movement times, and can track these against actual times in jobs. Subcontract operations are also catered for, with the facility to define supplier, costs and lead times. Multiple routes allow for the definition of alternative operation resources, such outsourced production, contract labor hire, and substitute machines or work centers, as well as for the separate definition of routings for items under engineering change control.
Multiple recovery rates allow for costing of the different routes, as well as what-if costing simulations. The routing provides the mechanism for calculating accurate lead times, as well as for calculating labor requirements and expected labor costs for jobs.
The structures functionality facilitates the definition of multi-level assemblies, formulae or recipes for manufactured products, including detailed material narrations and planned scrap, and provides input to the calculation of expected material requirements and costs for jobs. You can construct quantity or percentage relationships between assemblies, sub-assemblies and components, including relationships where the number of fixed components required is related to a quantity of the batch, and where the number of components required is fixed regardless of the batch. The Component Where-Used Query enables you to quickly establish exactly where a raw material or subassembly is used within a bill of material structure. The Replace Where-used program enables you to quickly replace an item with a valid substitute component in those bills of material in which it is used, thereby helping you to streamline the introduction of product design changes.
Blanket releases enable SYSPRO users to easily update call-off schedules for their OEM clients, as well as to reconcile the cumulative position against their OEM contracts. They provide the authorization to ship and/or produce against a blanket sales agreement or contract.
Available for stock items flagged as lot traceable in SYSPRO, expiry dates enable you to control automatic depletion of lots by sell-by or use-by date when issuing stock to sales and manufacturing, and can be factored into replenishment planning calculations.
When an item is received into stock, its shelf life is added to the date of receipt to calculate the default expiry date of the relevant lots. If you choose to deplete lots automatically by expiry date when issuing the stock, then lots with the oldest expiry date are depleted first.
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.
The system also 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's multi-level bill of material provides for up to 15 levels of parent/component structures, including made-in items, sub-assemblies, phantom parts, co- and by-products and raw materials. Once defined, costs can be rolled up through the bill to establish the cost of the finished part.
SYSPRO scheduling tools offer flexibility to address different levels of complexity and automation required to balance scheduling priorities, constraints and conflicts. While SYSPRO's Material Requirements and Work in Progress modules offers infinite capacity scheduling, as well as basic single-level forward finite loading for single constraints, SYSPRO Factory Scheduling (SFS) offers powerful finite backward, forward and bi-directional scheduling by job or resource. Creation and manipulation of schedules can be done manually or via automatic methods which allow for multiple constraints, including material availability in a multi-level bill of material environment.
SFS gives you the flexibility of executing or parallel loading (resource-based scheduling) based on preferred sequences. Preferred sequences determine what order the jobs and operations are going to be processed in any given work center. In job-based scheduling, loading is by due date, first in, or forward or reverse priority. In resource-based scheduling, each resource decides which operation to load next based on dispatching rules such as shortest setup time, closest to due date, user-defined attributes and critical ratio, with each resource having its own dispatching rule.
SFS provides advanced algorithmic rules to enable the implementation of sophisticated optimization techniques, such as minimizing idle work centers or total work-in-progress, scheduling around selected or dynamic bottlenecks, or minimizing overall setup. Furthermore, user-scripted rules enable the definition of user-defined sequencing priorities, such as by customer attribute.
SFS allows for automatic machine selection within work center, as well as the designation of machines as available for manual scheduling only. Furthermore, the path of WIP through the factory may be controlled through configuration of subsequent machine selections and 'if...then' scenarios; for example, if operation 1 is on an 8-inch drill, operation 2 must be on an 8-inch press. SFS also provides preferred resource selection for scheduling on primary and secondary machines. So the system can be configured so that everything is loaded on a primary machine until a specific threshold is reached, in which case a secondary machine is used.
SFS allows the configuration of relations between attributes on a specific resource, such as setup times when switching from one color to another. This feature, along with user-defined product attributes, facilitates the grouping and ranking of operations for a resource, based on match properties; for example: color, for optimizing changeover times; firing temperatures, for optimizing furnace usage; or cubic capacity, for optimizing space usage inside an oven or drying room.
Schedules are displayed on the SFS interactive graphical planning board, with highlighting of late, held and unscheduled jobs. Drag and drop editing with undo/redo options enables easy manipulation of operations, while validate and repair options help to ensure the integrity of a manipulated schedule. The system provides the option to save multiple schedules and compare them using Gantt views, while at-a-glance schedule performance metrics enable you to assess which is the best in terms of a variety of variables such as set up time, lead time, resource utilization.
Useful for informing the supplier contract negotiation process, supplier scorecards enable you to evaluate the importance and value of your suppliers to your business. The lead-time tracking functionality in SYSPRO's Inventory Optimization system enables you to evaluate suppliers in terms of their delivery performance, as well as their performance relative to other suppliers.
SYSPRO provides you with tremendous flexibility in delivering electronic and paper-based instructions to the shop floor. Using SYSPRO's user-friendly stationery format program, you can design multiple formats for documents, such as works orders, job tickets and material pick lists. For each format, the design tool enables the rapid selection of the relevant pieces of data, such as the job master details, component requirements and routing details, as well as the various types of narrations. The system provides the option of using anything from simple text-based documents, through bitmap-overlays and Word templates, to sophisticated documents formatted with SYSPRO's Crystal-based report writer.
Further enhancing this capability is SYSPRO's Multimedia facility, which enables product-relevant multimedia instructions and designs, such as video, drawings and technical documents, to be linked and viewed online.
SYSPRO's fully integrated solution enables the capture, tracking and analyzing of job and product costs, and profitability in real-time. Details of expected versus actual costs for material and scrap, internal and external labor, fixed and overhead costs per job, or group of jobs, is available through SYSPRO's querying, reporting and exception management features. These enable the identification of exceptions and problems as they occur, such as areas of high cost expenditure, production scrap and rework, and problems in the quoting process. Furthermore, the Job Cost Recalculation program allows you to recalculate the job expected cost totals for labor and material, thereby providing a more realistic comparison if allocations are added after the job has been created.