Accommodate variable end-products which result from regrading and unpredictable chemical processes
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 components 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.
SYSPRO's Work in Progress inspection system gives you the tools to record the inspection details of manufactured items and, depending on the results, select to receipt, scrap or rework quantities. Units in inspection are visible, but unavailable for use until accepted into stock. Within the inspection function, you can capture detailed records of counts, inspection, scrap, rework and stock receipts.
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 than what was originally planned.
Comply with local and international environmental and safety regulations
To comply with emissions regulations, such as the Kyoto Protocol and the US Clean Air Act, you must have the capability to record, track and measure your compliance initiatives and report on demand.
SYSPRO enables you to improve your capability to demonstrate compliance in your core processes, as well as implement a variety of control measures for stringent record-keeping to suit the level of vigilance required. SYSPRO's flexible features and integrated nature ensure rapid access to centralized compliance information across your business.
SYSPRO's multi-warehouse capability enables the separation, identification and tracking of compliant, non-compliant and quarantined materials. The customization features enable the configuration of screen highlighting of compliance deviations, as well as the automated notification of relevant personnel. Custom forms facilitate the definition of user-defined characteristics-such as the concentration of hazardous substances-against key data, such as products, materials, lots and serials, while the multimedia capability enables the linking of technical documentation, graphics and videos.
SYSPRO's Quality Management, Lot Traceability, Serial Tracking and Return Merchandise systems facilitate process control, quality tracking and traceability of raw materials and products, and the rapid extraction of information for efficient product recalls. Product versions are strictly controlled through the Engineering Change Control's workflow-based system, while informed selection of material and component suppliers is facilitated through performance scorecards and inspection data analysis.
Electronic signatures in SYSPRO provide rigorous transaction-level security, tracking and auditability, as well as the facility to trigger notifications and other actions, such as transferring data to 3rd-party applications and databases. On-demand compliance reporting is facilitated across the system by electronic signatures and SYSPRO Reporting Services, while SYSPRO Workflow services enable the consistent and rapid deployment of compliance processes.
Ensure Product Quality
SYSPRO's Quality Management System (QMS) enables product quality control by allowing the configuration of multiple measurement metrics, as well as inspection points per inventory item, such as length, chemical composition and hardness. This configuration, which includes the allowable tolerances for each metric and inspection frequency, is configurable as required; for example, full, partial, periodic and random quantity sampling is supported.
Exceptions to inspection rules are configurable per customer, supplier, operation and work center with quality inspection points at Work in Progress Inspection, Purchase Order Receipting, Sales Order Inspection and Inventory Inspection. These quality control checkpoints allow the collection of actual physical product data, to facilitate statistical process control, as well as provide an opportunity for simple material review in the event of a non-conformance, with the possible outcome of inventory reclassification or scrapping. Logs of all quality checks performed are held, including the details of the operators performing the check.
The advanced functionality provides the ability to escalate a quality issue or force quality actions to route into a material review board. The review board then has the facility to sanction the inventory action, such as approval or scrapping, and to record the relevant session details. Additional employee certification requirements for each product by checkpoint and operation are configurable and during all quality-related operations and reviews, this certification is recorded and used to determine if the operation at hand may continue.
Where a full QMS system is not required, quality checks may be implemented using the standard inspection facilities in the Work in Progress and Purchase Order modules. Purchased items can be flagged as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns are recorded. Units in inspection are visible, but unavailable for use until accepted into stock. Similarly, SYSPRO's 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.
SYSPRO's Asset Register provides the tools to simplify the management and control of your asset investment and to ensure a complete and current electronic view of the status of your asset register. It enables comprehensive tracking of all asset details and history, as well as tax, book and 10 alternate values. It includes integration to capex management, purchasing, work in progress and general ledger, thereby simplifying the asset acquisition and disposal processes and reducing the margin for input errors.
A variety of depreciation methods, basis and date conventions is available, as well as the facility to process depreciation adjustments. Revaluations and transfers are also catered for, as is asset stocktaking and asset expense tracking. Comprehensive reporting and querying is facilitated through asset master details, while user-defined groupings and categories enable the separation of registers by department, or other company-designated structures.
Manage operational costs in the mining value chain
SYSPRO provides essential integrated visibility to your accounting, distribution and manufacturing operations, thereby enabling you to easily identify and track your cost elements and to target areas of waste for improvement programs.
It offers Standard, Average, Last, FIFO and LIFO costing methods flagged at warehouse level, as well as actual-cost tracking, thereby providing accurate operations-focused inventory valuation, which in turn supplies accurate input for product pricing and profitability. Comprehensive multi-level costing of manufactured items is provided through SYSPRO Bill of Materials and Work in Progress.
SYSPRO's Activity Based Costing enables you to more accurately apportion overhead costs to specific products. The activity-based approach, where appropriate, seeks reasons other than volume to apportion overhead costs. AB Costing attempts to more accurately attribute overhead costs to specific products by applying them at the points of transition in the procurement, manufacturing and sales cycle.
SYSPRO's cost roll-up and implosion functionality, along with user-friendly costing queries, provides fast access to reliable information on which to base pricing and profit margins. In addition, its extensive what-if costing features enable modeling and comparison of the cost effects of alternative inputs for raw materials, production routes, labor rates and subcontractor rates.
SYSPRO provides work-in-progress tracking, enabling evaluation of detailed actual-versus- expected costs, as well as targets for cost savings and continuous improvement programs. Visibility to production scheduling, along with what-if sequencing and scheduling tools, enhance manufacturing agility and competitiveness and help to prevent lost sales in unpredictable demand environments.
Excess inventories tie up valuable resources both in terms of cost and warehouse management. SYSPRO helps you optimize, manage and track your inventories through its Inventory Optimization, Warehouse Management, Inventory, Material Requirements Planning, Purchase Order and Work in Progress solutions. In addition, the Purchase Order and Landed Cost Tracking systems provide a more accurate estimate of the full landed cost of imported goods, with the GRN matching and reconciliation features facilitating electronic reconciliation of supplier deliveries and charges.
SYSPRO's 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 security, repairs and maintenance or general expenses. It also eliminates the need to manually analyze such general ledger accounts.
Manage the storage, handling and transportation of hazardous goods
SYSPRO provides a number of features to assist you in the control and management of hazardous and dangerous goods with regards to storage, packing and transportation.
Multi-warehouse functionality enables you to create virtual warehouses, and bins within warehouses, to represent separate dangerous goods storage areas for specific items.
The multimedia features enable you to, per stock code, link and display graphical, video and text information, such as material safety data sheets, dangerous goods safety marks, and safety gear icons. Operators then have access to view and print the information when required.
The system's flexible custom form functionality enables you to capture dangerous and hazardous goods information per stock code; for example you can create mandatory or optional custom forms to capture data such as hazard identification number, class, subsidiary risk, compatibility group, packing group, shipping name and register reference. You can easily configure SYSPRO to display and highlight custom form data on operator entry and query screens; and to print on reports, such as picking lists and on stationery, such as job documentation, invoices and delivery notes.
SYSPRO also provides an extensive notes facility, the content of which you can configure to automatically print on certain documentation within the system. Notes include generic notes against all key fields, as well as special key field notes, such as the technical specification, dangerous goods handling, and inspection notes against inventory items.
Plan and control capex expenditure
For corporate governance requirements, as well as cash flow and operational efficiency, it is critical to budget for capital expenditure and to forecast the requisite cash requirements. SYSPRO's Asset Capex System facilitates the creation of both broad and specific capex budgets with the latter forming a subset of the broader budget category; for example, a piece of equipment within a production cell or line.
You can capture up to three quotations for a capex line and once the capex line is approved, you can rapidly generate a new purchase requisition, purchase order or a job, or link to an existing one. The approval process is controlled through a series of capex line statuses, including unapproved, approved, on hold and closed.
SYSPRO provides simplified acquisition processing once the asset is receipted from a purchase order or a job. The asset is placed in suspense and through a user-friendly suspense review facility you can retrieve and check the details of the suspended asset on-line before automating its transfer to the live asset register. This reduces double entry, as well as the margin for capture errors.
Comprehensive queries and reporting is provided on committed, uncommitted and spent capex values.
Plan and control preventative and breakdown maintenance
In the asset-intensive mining industry, plant breakdown or equipment failure can result in costly downtime and lost production that may be unrecoverable.
SYSPRO provides the tools to help you to ensure that maintenance operations are not compromised through stock-outs of critical inventory, whilst SYSPRO's e.net Solutions enable you to seamlessly integrate SYSPRO with best-of-breed CMMS systems.
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 maintenance plans. Independent demand for spares is 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.
Through the powerful tools in the Inventory Optimization suite of modules, SYSPRO enables you to better understand and quantify your risk profile. Key elements that drive inventory, such as forecasts, lead times, supplier performance and service levels, are coordinated, tracked and controlled to determine risk, evaluate supplier reliability and calculate optimal safety stocks. This is turn enables the modeling and formulation of more accurate target inventories and appropriate inventory policies.
Plan, execute and control production based on a wide variety of manufacturing modes
The diverse nature of manufacturing methods employed in the industry entails the synchronization and integration of a variety of manufacturing techniques all within one fully integrated software system.
Whether manufacturing to order or to stock, using discrete or process methods; engineering to order; or building large project-based assets, SYSPRO's outstanding flexibility ensures a comprehensive set of tools to help you plan, record, track and control your output.
SYSPRO functionality enables you to keep finished goods inventory to an absolute minimum and enhances your decision-making regarding what to manufacture, with what resources, when, where, and in what sequence.
SYSPRO's Quotations and Estimating ensures the integrity of cost and profit calculation for bid processes in project, as well as job shop, engineer and make-to-order environments. On confirmation of a quote, SYSPRO provides the capability to automatically raise all supply actions related to fulfilling the customer order, through its sales order, purchase order and job linking features. Furthermore, SYSPRO's Product Configurator facilitates seamless rules-based order processing for assemble, configure and make-to-order products.
For discrete and process manufacturers, comprehensive bills of material functionality enables the definition of simple single-level bills through to complex formulations with multiple units of measure and relationship definitions.
Master data features ensure accurate calculation of lead times and dynamic elapsed times, and assist in the optimization of production order quantities, while Engineering Change Control facilitates the efficient management of changes to product versions.
Planning features include forecasting, master planning, material requirements planning and capacity planning, while scheduling functionality extends from single-constraint scheduling to multi-constraint scheduling and sequencing.
Material and labor consumed in production may be backflushed, or, for longer production runs, issued as consumed to work in progress. Work-in-progress inspection functionality enables a product to be receipted against multiple items if grades of the final product vary.
Tracking of actual versus estimated labor hours, material usage and scrap is facilitated through the Work in Progress module, while SYSPRO's e.net Solutions enable version-independent integration to best-of-breed CAD and shop-floor data collection systems.
SYSPRO features extensive costing control and tracking, including the facility to model the effects of what-if material, labor and manufacturing route costs.