Bills of Manufacture (BOMs) DTR Plastics ERP BOMs drastically reduces data entry by integrating directly into quoting. Using the BOM feature, you can accurately establish production standards and project item costs (for each plant location). Cost calculations account for regrind, scrap, purge, return of regrind to inventory, labor, overhead, stations, packaging, setup, tooling, sub-contracting, and warehousing.
Your production team can identify build-to-stock jobs with minimum and maximum reorder levels, standard stock colors, and/or custom orders right in the BOM. What’s more, your scheduler can create and schedule jobs based on your standard stock levels or custom orders. In addition, you have the ability to capture costs within the BOM and schedule secondary operations. To ensure accuracy in your use of materials, DTR Plastics ERP supports the attachment of drawings and specs to sales orders, BOMs, and work orders.
Benefits:
Manage family and multi-cavity tools.
Account for regrind, scrap, purge, and return of regrind to inventory within your costing model.
Adjust cavities item/total used in your mold as conditions change.
Track different costing at individual plant locations using multiple BOMs.
Create quantity price break tables with margins automatically from the BOM.
View all BOM components in tree format.
Perform alternate routings.
Generate up to five product configurations (e.g., quantity, run rate, scraps percentages) per BOM.
Designate machine assignments for scheduling.
Forecasting and Rough Cut Planning DTR Plastics ERP’s forecasting module automatically selects the most accurate forecasting method so you can easily calculate quantities for rough cut capacity planning, budgeting and scheduling. You can generate forecasts by the week, month, quarter and year. Plus, forecast data can be calculated by applying a factor to current sales orders or you can enter the information manually. Your forecasters can:
Adjust data to smooth the “highs and lows.”
Use batch utility programs to automate the task of collecting large amounts of data.
Have multiple forecasting tools available such as manual, side-by-side and statistical methods (moving average, double moving average, exponential smoothing, and linear regression).
Reference unlimited future and historical periods.
Display sales history and allow for sales history adjustments.
Perform multiple forecasts on each (or any combination of) item code, plant location, salesperson, territory, customer, and shipping location.
Forecast a group item and have forecasts created for all members of that forecast group.
Forecast a new item with no sales orders.
Rough Cut Planning
DTR Plastics ERP uses the data from forecasting and BOMs to produce detailed manufacturing information that you can use to create your annual operating plans. You will have the data you need to answer critical planning questions. Your team can turn to the rough cut planning application for:
Projections on raw material expenditures each month based on sales forecast.
Reports to see if press capacity will be exceeded.
Projecting labor requirements by month for each product line.
Benefits:
Generate weekly, monthly, quarterly or yearly sales forecasts.
Answer long-term planning questions such as, “When will I need to add more manufacturing capacity?”
Plan for future material expenditures and labor hours by month for each product line.
Material Requirements Planning (MRP) With the MRP application, you can project the requirements for all materials based on scheduled production, sales orders, and back orders. MRP helps you to reduce the cost of on-hand inventory while ensuring critical materials are in stock to meet production schedules.
You have the capability to report on inventoried items, backorders, and vendor lead times. In addition, it’s easy to display quantity on-hand, demands for production or sales, outstanding purchase orders, and vendor information using the MRP query feature.
Your production staff can use the MRP query feature to view material requirements or subcomponents (work in progress) by minimum/maximum inventory levels and expedite or postpone orders for raw materials. In addition, purchase orders can also be created directly from the MRP Query details.
Benefits:
See when demand exceeds quantities on hand and in existing purchase orders.
See when demand exceeds current quantities on hand but not in purchase orders.
Summarize all raw material requirements in a color-coded query.
Drill down into the details by date and demand source.
Scheduling DTR Plastics ERP features a robust drag and drop scheduling control center. Your production scheduler can generate forward finite, queued, and just-in-time scheduling for all your workstations and secondary operations. In fact, it’s easy to schedule all your jobs, at all levels, on just one screen. Within the scheduling control center, you can instantly see where sub-component and assembly jobs are scheduled and identify late jobs, material shortages, and available stations and tools.
If you choose to reschedule a job on a different date or move it to another workstation, the scheduling control center will automatically reschedule all associated lower level jobs to help you meet your shipping dates. In addition, scheduling helps you gain visibility into machine setup and tear down times, preventative maintenance, tooling, and raw material shortages.
Production schedules can be based on sales orders, forecasts, release orders (EDI), manual assignments, consolidations and/or reorder points. This helps to maximize machine utilization and efficiently determine production schedules. With the graphical scheduling application, you can:
Maintain the integrity of multi-level jobs.
View bottlenecks in multi-level jobs.
Consider set-up and tear-down times as well as preventative maintenance.
Drill down into details of a job or station.
Save and recall multiple scenarios.
Identify where raw materials are used in production.
Schedule by multiple plant locations, departments and multi-tool stations.
Share data with forecasting and MRP.
Plan for tool setups, family molds, and tool conflict resolution.
Print work orders from scheduling.
See a graphical view of materials and work-in-process requirements.
With the scheduling control center, your employees can analyze raw materials for each job at each plant location. Based on color codes, it’s easy to display all demand, identify shortages, and classify jobs with no material problems. Your scheduler can click on any job to view item breakdowns, including raw materials and work in process required for each job, availability of materials by plant location, sales orders/jobs, and jobs created from minimum/maximum levels. Production has additional visibility into outstanding purchase orders and can determine if orders will be on time or late while plant managers can quickly see which materials to pull to the shop floor by shift.
Benefits:
Schedule all your jobs, at all levels, on just one screen.
Identify potential late jobs, raw material shortages, and available stations and tools.
Reschedule a job and DTR Plastics ERP will automatically reschedule all associated lower-level jobs to help meet shipping dates.
View bottlenecks in multi-level jobs.
Plan for tool setups, family molds, and tool conflict resolution.
Drill down into the details of a job or station from the scheduling control center.
Product Costing DTR Plastics ERP’s cost matrix can help your customer service team generate simple or more detailed quotes. Since accurate project costing is critical to your success, the system supports detailed cost management and automatically distributes costs across all related job operations. Your staff can:
Create payroll timecards—interface to DTR Plastics ERP’s payroll module.
View time card entries on your screen for editing.
Automatically create journal entries.
Store past job history information.
Allocate “late” vendor invoices to one or more jobs.
Manage sub-contracted jobs.
Variance Reporting DTR Plastics ERP contains many standard reports that you can access at a moments notice—making it quick and easy to get project costing data out of the system. Some standard reports available to you include:
Percentage of completion reports.
Standard to actual costing (in graphical format).
Cost overrun projections (in graphical format).
Actual versus estimate (hours and dollars).
Quote versus estimate versus actual.
By job or project.
Material costed to jobs, materials received and unallocated, time card activity, and tooling revisions.
