one4all

Production industry has been facing a whole host of challenges whose meeting could be helpful with the use of the latest IT tools and systems.  Increasing customer demand with respect to quality with simultaneous reduction of lead times, increasing need to control labour costs and enhance human resources management in production processes, difficulties in planning optimum stock levels, problems with monitoring staff work and efficiency of production machines, calculating actual production costs or shortening product life (involving the need to market new products) are just some of them.

In case of companies dealing with discrete manufacturing, the above examples additionally include challenges related to planning of production processes, calculating actual costs of product manufacture and monitoring the work in progress, and sometimes the need to “construct a non-standard product”, its assessment and provision of a deadline for a given order already at the commercial stage.

Syntea Business Solutions, on the basis of its experiences to date, has developed a proprietary solution dedicated to discreet manfacture industry, which was built on the logic of a production module and configuration module of Microsoft Dynamics AX and is available directly in the system.

one4all for discreet manufacture ensures especially:

• production workers’ timsheets and reflection of actual costs in the value of goods and the work in progress,
• streamlining processes of ordering, planning and production of goods,
• optimization of production planning processes,
• stock levels optimization,
• provision of information about price and order delivery date to customers already at the moment of placing an order,
• provision of data outside – to suppliers and recipients (for purchase order suppliers, recipients of the orders and delivery dates),
• electronic interchange of documents with customers and suppliers (EDI),
• possibility of demand planning,
• reduced error probability owing to specification of criteria for particular products which are then used in creation of individual orders,
• automatic BOM and MPS generation after product configuration,
• possibility of fast and easy introduction of changes in product specifications which are immediately reflected in BOMs; this eliminates the need to change BOMs manually.

one4all for discreet manufacture includes the following modules:

• production planning and production management,
• warehouse and logistics managemament,
• quality control,
• customer relationship management (CRM),
• sales management,
• HR and payroll
• financial management and management reporting.

Production planning and production management

one4all for discrete manufacturing provides for balanced planning and management of the entire production process. Production planning and scheduling is based on accepted orders or entered sales forecasts and production orders generated on their basis. Detailed schedule specifies types of goods which should be manufactured and their expected deadlines of getting off the production line.  Also, we may observe actual inventories of specific goods in specific company warehouses as well as execution plans for all goods in subsequently scheduled weeks. Additionally, it is always possible to view progress of individual production orders and check which part of a given production order was already delivered, on what shifts, by what teams, and check whether any mistakes were made during the production process, and if so, what shortages they account for.

one4all for disrete manufacturing enables accounting for production excluding the value of the waste material. In standard applications, calculations of the technical production cost always considers the value of waste materials (cost of waste materials is added to every raw material, product, component). Some products might not generate any waste materials. Our functionality provides for selecting goods (raw materials) which should not include the cost of waste materials during calculation of the technical cost of production (the value of goods in relation to the cost of a raw material remains as recorded during production estimate).

The module of production planning and production management especially includes:

• production planning and scheduling,
• planning of production orders pursuant to sales forecasts and orders entered on an ongoing basis,
• production considering complex formulas and multiple BOM levels,
• electronic order circulation – in case of using an external system, an interface for exchanging data regarding production plans was also developed,
• interface for exchanging data with an external system of production equipment management,
• calculation of technical production cost excluding the cost of waste materials – handling of production orders for goods in retail packaging and bulk packaging,
• tracking of production orders, deadlines and degree of delivery of future sales orders,
• calculating volumes of necessary packaging.
• production considering complex formulas,
• integration with production equipment providing for detailed planning and scheduling of orders,

Warehouse management and Logistics

one4all for discrete manufacturing provides mechanisms enabling exchange and processing of data pertaining to purchase orders, sales orders and production orders with the warehouse, directly via ERP system or through integration with an internal system. This accelerates setting of orders and gives an opportunity to control product expiry dates (batch tracking). Combination of a financial system with the warehouse management system speeds up the process of handing over the goods from the warehouse, saves time, money and warehousing space as well as facilitates partial or total stocktake.

This functionality also helps to generate the full list of inventories and the work in progress. This is possible owing to the labelling of each pallet. Labels are generated directly from the system and their identification is facilitated by a barcode. The code enables the storekeeper to, e.g. obtain information whether a given pallet should be moved for production or returned due to identified defects.

This module especially provides for:

• obtaining immediate information about delivery dates or partial delivery dates for a given order – automatic summing up of inventories and the work in progress,
• planning handovers using ATP (Available to Promise) function considering pending orders,
• accelerating setting and handover of supplies, optimum distribution of goods in the warehouse and controlling product expiry date (batch tracking),
• partial and total stocktake,
• automated collection of orders from different branches and booking of raw materials,
• comprehensive barcode services and identification of goods in stock,
• printing job descriptions for production positions.
• high storage warehouse service

Quality controls

In order to facilitate raw materials quality control, the system is equipped with tools comparing parameters of supplied materials determined by the technologist with obligatory production standards and technologies. Also, it is possible to determine individual standard levels for particular suppliers. Results of raw materials analysis are compared with data provided by the supplier. In case of any departures from the standards, the system will automatically indicate which standards are exceeded.  At the production stage, the system supports quality control by ensuring compliance with parameters enabling meeting of specific standards (including compliance with ISO 14001 environmental management standard or Polish PN-N 18801 occupational health and safety standard). Additionally, quality control covers recording of machines and equipment as well as product tagging and labelling.

The solution also ensures controlling deviations of material costs from normative costs assumed in formulas of goods manufactured during the production process. Thus, it enables running of extensive analyses and controls of the flow of materials in an enterprise and their optimum use in the production process.

This functionality especially provides for:

• controlling quality of used raw materials and tracking batch numbers throughout the entire production cycle (from procurement to sales),
• controlling quality of the final product – owing to storing the results of external and internal controls,
• tagging the product with labels compliant with Polish standards or with internal labels.

Customer relationship management (CRM)

This module allows to focus on customers and their needs and on buliding long-term relations with the customer. Any customer information and any action performed in relation with the customer is reflected in the system. Therefore, we are building a database of former, existing and potential customers, which allows us to closely track their behaviours, changing needs, choices and purchasing history. CRM module allows for greater automation of actions necessary to acquire new customers, which contributes to increased effectiveness and more efficient use of sales representatives work. CRM module provides specific information regarding planned revenues, margin level and compliance with the budget, it facilitates monitoring of conducted commercial projects on all levels.

Customer relationship management (CRM) includes:

• managing business relationships and business contacts,
• managing sales opportunities and trade offers,
• managing contacts,
• integration with Outlook mail (tasks, calendars, alerts),
• integration with telephone exchange,
• generation of reports and diagrams,
• preparation of sales budget.

Sales management

one4all for discrete manufacturing supports the sales management and logistics processes. It allows for controlling and managing the work of shop assistants, planning future activities on the basis of current information, more effective customer service and especially sales process optimization by possible analysis and increased effectiveness.

This module especially provides for:

• managing sales orders, receipts, returns and correcting invoices,
• managing bulk orders and exemption orders,
• managing advance payments and issuing of advance invoices,
• multi-currency sales,
• supporting different forms of payments (transfer, cash on delivery, cash),
• use of different inventory valuation methods (FIFO, LIFO, weighted average, fixed price),
• managing alternative goods,
• easy implementation of extended discount policy owing to the functionality of automatic discount and price reminders for particular customers,
• calculating provisions for customer bonuses,
• allocation of additional charges (e.g. transport or assembly fees),
• managing intercompany orders within one and the same application,
• preparation of credit analysis for a given payer,
• reporting on compliance with the budget.

HR and Payroll

This module offers end-to-end HR and Payroll services for the enterprise. It supports the user in timely and accurate payment of salaries and proper calculation and payment of taxes and social security premiums.  Flexibility of the module allows for settling of payroll elements resulting from internal regulations bidning in etery company. It also provides for HR services mainly related with drawing up and proper keeping of necessary documentation. Recorded information therefore includes education, qualifications, occupied positions, work places, awards and penalties for each employee. This module provides support for HR and Payroll department employees in recording and accounting for the working hours, which is particularly important in production companies.

This module especially provides for:

• registering operations of employees working on production lines and effecting settlements of particular actions or operations - record forms might be provided directly in production departments together with registration of barcode systems, data related to recording of individual operations on production lines will then be used in the process of salary calculation,
• possibility to check validity of obligatory courses/vocational qualifications of employees, periodic health examinations, as well as controlling expiry of contracts concluded for specified period of time,
• current payroll services,
• integration with Płatnik software – by generating and transmission of information to the Social Insurance Company (ZUS),
• automatic generation of tax declarations: PIT 4, PIT 11, PIT 40, PIT 8A, PIT 8B,
• possible employee settlements against employee benefit funds,
• recording employee absence related to sick leaves, sick leaves for family care, maternity leaves, holiday leaves, unpaid leave and non-standard absence,
• extensive set of reports, analyses and statements – such as: slips, lists, joint tables, sheets, cash lists, reports of covered absences, sorted banknotes.

Financial management and management reporting

Along with company development, business needs with regard to financial management and the use of management analysis gradually increase. The use of functionalities incorporated in the solution ensures access to analytical data providing for its multidimensional analysis and more efficient use of funds.

Financial management and management analyses mean in particular:

• end-to-end financial analysis, in accordance with IAS and the Polish law,
• cash flow management,
• budget management,
• electronic mutual data exchange with the banks and other institutions,
• extensive possibilities regarding management analysis,
• possible drawing up of any number of individual financial reports based on financial accounts and combinations of analytical aspects,
• liability management – data updates (stocks, sales settlements, commercial analyses),a set of template reports, such as: reports on discounts granted, list of physically available stocks, sales reports – fast reporting by individual companies (in case of multi-branch companies) and drawing up of joint statements,