Adopt LEAN manufacturing practices
From enabling the identification and tracking of non-value adding activities inherent in your current operational processes, to the automation of manual processes, SYSPRO's powerful functionality provides you with the tools to implement your LEAN initiatives. Its integrated nature and ease-of-use facilitates the effortless extraction of financial and operational information required for Value Stream Mapping (VSM).
SYSPRO's Inventory module is a synchronized hub providing a consolidated view of all stock locations and those activities that impact inventory optimization and customer service levels, as well as the end-to-end elements of costs and lead times. Features such as Pareto and obsolescence analysis can assist in identifying those products that are suitable for VSM focus, while SYSPRO modules such as Engineering Change Control, Bills of Material, Work-in Progress and Factory Scheduling facilitate the evaluation of targets for kaizen programs, such as reduction in design and manufacturing costs, cycle times, queues and setups.
SYSPRO's powerful inspection, serial tracking and lot traceability functionality aid in the identification and tracking of the source of defects, thereby enabling the implementation of kaizen initiatives towards the principle of 'Quality at the source'.
The queries and reports in Work in Progress enable you to quickly assess the statuses, inventories and costs associated with work in progress, and provide metrics on utilization, efficiency, scrap and rework, while customer and supplier delivery performance metrics are provided by the Sales Order and Purchase Order and Inventory Optimization modules.
SYSPRO's Inventory and Bills of Material modules enable the modelling of the LEAN techniques of batch size and setup reduction on costs, lead time and inventory. SYSPRO's Factory Scheduling provides graphical tools to assist you in optimizing scheduling and sequencing processes, to reduce setup and overall lead time, and improve manufacturing flexibility and sale-to-customer flow. This, along with the inventory optimization and production planning features, enables you to refine the pace of production to match the pace of sales. Furthermore, features such as sales order/job/purchase-order linking facilitate the electronic implementation of true pull supply- chain processes where appropriate.
Document Flow Manager and SYSPRO e.net Solutions enable you, not only to automate resource and time-intensive processes such as order processing, but also to handle increased volumes from global customers. By providing the capability for 24/7 order taking and acknowledgment, they improve lead time, and free up staff to perform other value-adding tasks. Furthermore, SYSPRO's XML-aware solutions enable version-independent integration with best-of-breed shop floor monitoring and control systems.
The system's sophisticated reporting and analytics tools enable user-defined reports and queries, while SYSPRO Workflow Services enable the creation of efficient workflows to implement business rules and standardize business processes. Electronic Signatures and automation tools enable the automatic raising of alerts, triggers and events based on user-defined criteria, thereby aiding prompt problem solving and process improvement.
SYSPRO's flexible integrated features and best-practice focus give you single-point visibility and control, providing support for the implementation of your LEAN initiatives.
Control product design changes
Constant innovation is one of the key factors to remaining competitive and on-going research and development to design new and better products is integral to the industry. Your ability to design new products and modify existing designs, as well as improve time-to-market is critical to remaining competitive and profitable.
SYSPRO provides tools to streamline and track the introduction of new product designs and amendments to existing designs, along with relevant costings. SYSPRO's Engineering Change Control (ECC) enables you to apply strict control over your design-to-market processes 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. ECC's queries, audit trail, history and archive facilities, give you quick on-line access to details of prior product versions, as well as the option of reverting to the production of a prior product version if required. In addition, the facility to attach copies of product design drawings to version and release levels provides access to visual details of revisions.
The Where-used Query facility enables you to identify all items affected by the raising of an Engineering Change order for all routes identified as being under Engineering Change Control. In addition, SYSPRO provides a 'replace component where-used' facility that enables the quick replacement of one item with a valid substitute item, thereby streamlining design changes.
SYSPRO's ECC, Bill of Materials, Work-in-Progress and Factory Documentation modules enable you to implement controls to ensure that your products are manufactured under consistent processes, to the correct designs and specifications. Single-level, multi-level, co and by-product bills are all catered for and flexible bill definitions accommodate complex component and sub-assembly requirements.
Improve electronic collaboration with trading partners
Your ability to harness e-Commerce technologies effectively has enormous potential to transform your business and enhance commercial success and growth.
Your customers and suppliers may look increasingly to closer collaboration, to cut production timetables and minimize disruption to their supply chain. This could involve working via their electronic order and supply chain systems to enable streamlining of operations and to reduce margin for error. Multi-organization research and design teams may need to work collaboratively and to achieve this, you must have efficient, secure systems that can deliver and receive information.
SYSPRO 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.
Quick response times and accuracy in fulfilling orders are critical to your reputation in a diverse and demanding global market. Automated 24/7 customer order placement and acknowledgment is facilitated via SYSPRO's Document Flow Manager and email. In addition, SYSPRO's e.net Solutions enables the rapid development of applications for mobile devices, so that your sales force can check stock and place orders directly into SYSPRO while out visiting customers, thereby improving order turnaround time.
SYSPRO's e.net Solutions can be extended to integrate SYSPRO with other applications, such as shipping companies' tracking systems to determine the shipping status of customer orders. In addition, e.net Solutions facilitates the integration of SYSPRO with scanning and Smart technologies, thereby streamlining picking and packing processes, as well as inventory stock takes.
If your customers include Original Equipment Manufacturers (OEM) you can import and easily reconcile vendor EDI releases using SYSPRO's Blanket Sales Order module.
Maximize profitability in a low margin environment
Maximizing your profitability is only possible with an accurate picture of your costs. With operational costs consuming a high percentage of your revenues, we understand that maximizing yield and keeping strict control of costs and reducing waste in all areas of the business is essential to your on-going profitability.
SYSPRO enables you to implement continuous improvement by giving you visibility to costs and profits across the business and helping you to identify points of waste as they happen. This includes variations in expected and actual raw material and production costs; late supplier deliveries; obsolete, slow-moving and excessive inventories; and product defects and scrap. In addition, the Bill of Materials What-if costing feature enables you to model possible changes in raw material and labor costs and see the imploded effects on higher level item costs and profits.
Optimize production capacity and increase manufacturing efficiency
Increasing manufacturing efficiency means getting the right balance between demand and supply, while optimizing capacity, improving throughput, and reducing waste and variable costs. SYSPRO provides interactive decision-support tools that give you visibility and control over all inputs and outputs.
SYSPRO's material requirements planning functionality gives you an integrated picture of your time-phased demand and supply, enabling you to model 'what-if' scenarios to produce viable replenishment plans.
SYSPRO Factory Scheduling assists you in maintaining accurate and up-to-date production schedules that take account of your material plans and the complexities of your factory. This enables better co-ordination between work centers, increased productivity, reduced work-in-progress and achievement of improved customer service levels.
Material and labor tracking, as well as cost, scrap and utilization management is facilitated through SYSPRO's Work in Progress module, which enables you to track in-process production at every stage and identify problems as they occur.
Synchronize supply with customer demand
Particularly for component and material suppliers of original equipment manufacturers (OEM) synchronizing supply with customer demand is a key requirement to prevent costly line stoppages in assembly plants. This involves not only automating order processing and other processes in the supply chain, but also executing production plans using LEAN principles.
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. SYSPRO Blanket Sales Orders enable 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. SYSPRO's Requirements Planning and Factory Scheduling 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 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.