A workable manufacturing system must reconcile engineering intent, available material, machine capacity and what operators actually complete. We build ERP and line-of-business software that carries that context from quotation and planning through production, inspection, despatch and costing.
Operators need a fast way to report starts, completions, scrap, downtime and material use without turning every action into clerical work. Shared terminals, scanners and intermittent connectivity make timestamping, identity and correction workflows particularly important.
A revised component or routing must not silently alter work already released under an earlier design. Effective dates, alternates, substitutions and as-built records must distinguish the current engineering definition from the version actually manufactured.
MRP can suggest material dates while ignoring whether a qualified machine, tool or crew is available. Expedites, breakdowns and rework then disrupt the sequence, so planners need constraint-aware schedules and a controlled way to override them.
Traceability crosses purchased lots, split batches, subcontract operations, inspections and finished serial numbers. A useful genealogy must survive unit-of-measure conversions and reversals, and support targeted holds rather than blocking unrelated stock.
Standard cost alone hides yield loss, setup time, rework, subcontract charges and variance caused by material substitution. Finance and operations need the same rules for work-in-progress valuation and job close, with late transactions handled explicitly.
Generic ERP tends to model production as a simple issue-and-receipt transaction. Real plants have co-products, variable yields, overlapping operations, outside processing, substitute materials and partial completions. Configuration can cover some variation, but dense custom fields and spreadsheets usually appear when the underlying transaction model cannot represent the work.
We define the item, revision, routing, resource and inventory ledgers before choosing screens. Released orders retain their production basis while approved changes flow to future orders. Exception queues expose shortages, overdue operations, quality holds and uncosted activity without rewriting historical records.
Manufacturing integration spans CAD or PLM item releases, barcode and RFID devices, scales, PLC or MES events, supplier portals, carriers and finance. Those sources use different identifiers and time semantics. We place validation and idempotency at the boundary so a retried machine event does not double-report production and an unrecognised part does not create an accidental item.
Interfaces can use APIs, files, message queues or industrial gateways according to what each system supports. A canonical mapping records units, time zones, revision references and source transaction keys. Failed messages enter a visible reconciliation workflow; operators can correct mappings without losing the original payload.
The first phase establishes item masters, units, locations, bills, routings and opening inventory. A representative product family then proves order release, material issue, reporting, inspection and close from end to end. Running a narrow slice exposes master-data and costing problems before they affect the whole plant.
Later waves add scheduling, maintenance, advanced quality and supplier collaboration, plant by plant or value stream by value stream. Cutover plans account for open purchase orders, partly completed work, quarantined stock and transactions entered during the count. Ownership passes to operational teams through role-specific procedures and controlled configuration.
Yes, one planning model can support make-to-stock, make-to-order, engineer-to-order and mixed policies by item or product family. Allocation, pegging and costing rules must be explicit so customer-specific supply is not consumed by a forecast order.
We profile item codes, units, revisions, effectivity, operation sequences and duplicate structures before import. Trial loads produce validation reports for engineering owners, and released work orders are treated separately from future product definitions.
Not necessarily. PLM may remain authoritative for engineering release and an MES may continue detailed machine execution; ERP can coordinate demand, materials, inventory and financial consequences through defined interfaces.
Transactions link received lots and serials to issues, operations, transformations, inspections and finished output. Corrections are posted as traceable reversals or adjustments rather than edits that erase the original chain.
Yes, capture clients can queue authorised transactions locally and synchronise when connectivity returns. Conflict, ordering and duplicate-submission rules are designed for each transaction type rather than relying on last-write-wins.
Share the workflows, records, exceptions and integration boundaries the system needs to support. We will help define the technical scope.