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Beas Manufacturing

Extended production Beas for SAP Business One – enterprise solution for discrete, process and design manufacturing.

Nowadays, customers’ expectations regarding the quality of service have increased significantly. Each entrepreneur tries to do everything so that the customer interested in the offer receives the necessary information as soon as possible. This approach most often requires the provision of fixed dates for the delivery of products, e.g. each order is completed within two weeks. In times of high competitiveness, this approach is no longer sufficient. It is worth implementing a tool that will allow you to provide information and plan the delivery of the product to the customer as soon as possible.

Materials management

Version / Version Control

Managing the production order

Quality control

Maintenance

Planning and scheduling

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Beas extended production

It helps to prepare all the necessary data that can be used later to plan production, i.e. correctly set production goals.

This means prioritizing their importance, specifying tasks that should be performed in the right order, and determining the resources necessary to achieve them. Simply put, it is a kind of designing the future. Planning has to answer a few key issues:

  • What exactly do you need to produce?
  • How to do it (what resources, raw materials, operations to use)?
  • At what time?

Production planning must take into account the technical, organizational, economic and management issues that are interconnected.

Beas offers the best methods and workflows that fit large industries such as metal and plastic processing, machinery and apparatus, electrical and electronic appliances, automotive, packaging, chemical engineering and food.

Beas extended production is dedicated to process, discrete and design production, which in practice means excellent coverage of most of the needs of production companies, not only in Poland.

The solution is multilingual, therefore it can be used by many users in many countries. Connection with SAP Business One allows you to manage all areas of the enterprise from one application and one database, and does not require any integration.

 

 

 

 

The production area is closely related to other areas of the company’s activity, such as finance and accounting, human resources and payroll, and warehouse management. The production area includes additional support areas such as:

  • basic information
  • materials management
  • version / version control
  • management of production orders
  • quality control
  • maintenance
  • APS planning and scheduling
  • MRP / MRP II
  • production reporting
  • production cost calculation
  • product / variant configurator
  • PDM and SCADA integrations

Source data is the basis for the implementation of business processes throughout the company, as well as for information gathering and decision making. Beas Manufacturing complements SAP Business One to provide the information SMBs need for manufacturing management, cost accounting and control. Material files, resource files and tools allow for a very broad description of the details used in the planning, quality control or material requirements planning process. The high level of detail of the master data allows for precise preparation of the production technology with a multi-level tree structure, full route, using the resources and tools used during production.

Examples of extensions in the field of master data in the system:

Beas Manufacturing functionalities

beas_zarządzanie-materiałami

Materials management

Manufacturing functions adopt specific strategies for material management such as Make-To-Order and Make-To-Stock, mixed and variant production, …

… as well as functions necessary for proper production planning and order fulfillment. The materials described in the master data area are much easier to manage because the task of monitoring all constraints, deadlines and conversion rates is configured on the Beas side.

Materials management:

  • Many models of material requirements created in accordance with the expectations of customers and the optimization of warehouse space.
  • Backward postings based on job demand.
  • Extended batch and serial number processing.
  • Data collection on mobile devices for warehouse / storage locations.
  • Additional goods receipt control options, including blocking a selected batch, part of a batch and release for production.
  • Unplanned postings based on labor requirements.
  • Extended inventory management.
beas_kontrola-wersji

Version / Version control

This function is dedicated to enterprises whose production is characterized by high variability. It allows you to produce a large amount of a modified product …

… without the need to create many indexes in the database that differ only in details such as color or additional equipment options.

The versions may differ from each other not only by changes in the bill of materials but also in the route. An important feature is keeping the main material index unchanged and the ability to copy it to the next version and introduce only the necessary modifications in line with the customer’s expectations.

The versions can be controlled at the BOM level, but also the routes at any number of levels in the product tree structure.

Option to view information about the variant:

  • active,
  • inactive,
  • released,
  • blocked,
  • change history.
beas_zarządzanie-zleceniami-produkcyjnymi

Managing the production order

Production orders are the basis for the automatic production planning system and material requirements. They are created on the basis of orders …

… placed by customers or an analysis of the inventory of finished and semi-finished products and a mixed model. A production order is based on a prepared production technology, however, it additionally takes into account additional factors resulting from the customer’s expectations, such as delivery on a set date and exact quantity.

Requirements are calculated for a specific production order and electronic documents are generated, e.g. purchase orders or batch acceptance to the warehouse.

Of course, production orders can be generated automatically using the MRP II function.

A production order may be:

  • generated on the basis of sales analysis
  • generated from a sales order
  • generated manually directly by the system operator

A production order may be modified at any time,

which means great flexibility in managing its course in time. It is possible to add new raw materials or replace the existing ones, remove raw materials, add an additional quantity needed to complete production, change the route (add or remove technological operations) or the tools used.

From the production order, the operator can see

what operations have already been completed and what materials have been reported as used, what shortages or waste have arisen. Important information available on each production order is the resource load and whether a given operation is started, paused or completed.

Quality control

In addition to meeting high quality standards, mostly small and medium-sized manufacturing companies must also document them.

Production Beas for SAP Business One offers functions that allow you to perform the necessary quality tests during the material flow, from the original purchase for production to the shipment of the goods. Different types of test orders can be assigned to external as well as internal work steps (operations).

Quality control can be qualitative or quantitative

  • Qualitative – it comes down to describing the controlled raw material / semi-finished product / finished product with a set of descriptive features or technical parameters, taking into account the standards / tolerance ranges which may or may not be used for further processing or sale.
  • Quantitative – entering information in the form of a selected measurement unit, e.g. items with the possibility of conversion into alternative units.

Quality control can be inter-operational, final, ad-hoc, i.e. triggered at any time and performed on mobile devices, such as e.g. a tablet.

The module includes, among others

  • Management of quality control plans – the ability to create plans for selected key customers or products that determine the company’s income and the quality control process is critical.
  • Quality control for orders, from receipt of goods, through production and delivery
  • Expiry date monitoring
    Approved / blocked for checking, batch and serial blocking for parts
  • Receiving and analyzing complaints about customers, suppliers, internal production

Maintenance

Ensuring control over the operation of machines and an appropriate production plan allows you to maintain the continuity of processes …

… and increase efficiency. The system offers the possibility of planning the frequency of service activities, reducing the likelihood of unexpected failures of machines and their components. Tool changes, scheduled maintenance and retooling after a specified number of cycles or machine runtime reduce the risk of failure and better plan costs.

The maintenance functionality allows you to:

  • Management of the resource base and tools
  • Planning service activities in a manual or automated manner
  • Planning the wear of tools and ordering them at the right time with the possibility of automatically generating a service order for tool replacement or its calibration.
  • Recording failures and downtimes and informing responsible persons using various communication channels such as e-mail, information on the user’s screen or SMS.
beas_planowanie-harmonogramowanie

Planning and scheduling

The APS (Advanced Planning and Scheduling) function is used for detailed planning in enterprises when order times, lead times, transition periods, …

… capacity allocations, resource availability are critical parameters in the value creation process. By graphically visualizing and comparing all activities with resources, you get a high level of transparency when you need it.

Some of the most important planning features:

  • Possibility to choose which production orders will be planned, which are frozen for planning, i.e. without the possibility of changing their deadlines.
  • Possibility to manually change the order of order execution through the dragging mechanism.
  • Various ways of organizing and planning the sequence and optimization, e.g. by business partner, delivery date, with / without limitations of production capacity limits.
  • Possibility to create your own planning scenarios for the selected type of production, e.g. MTO (production to order), MTS (production to stock), ETO (production according to customer specifications), ATO (assembly to order).
  • Include dependencies in multi-level procurement with cross-check of delivery dates.
  • Simple selection or replacement of resources such as machines or tools.
  • Integrated material availability calculation can be turned on or off, and reporting will automatically inform you what parts are missing during each planning and scheduling process.
beas_harmonogramowanie

Scheduling

In order for the implementation of the production order to take place in accordance with the previously prepared plan, technological operations …

… should be assigned to appropriate resources and groups of resources (production cells) with appropriate competences and performance. These can be single resources or groups of resources, e.g. production cells, in order to facilitate load management within the group. In order to flexibly approach the scheduling process, it is necessary to allow the user responsible for the scheduling process whether the queue at the position is set top-down without the operator’s interference or he can choose which operation and on what resource he can perform. Both cases are feasible and largely depend on the type of production.

The user should be traceable

using dynamic Gantt where there are delays in implementation with the possibility of manual change / postponement of operations in time Scheduling can be simulated for production resources and technological operations.

Important

The way in which the production technology is built has a great influence on the scheduling process. If we can plan the process in such a way that the tree consists of semi-finished products, then we will achieve greater flexibility in terms of planning and scheduling.

MRP / MRP II – material procurement and production capacity planning

Beas Production is equipped with advanced tools for planning production needs. When planning requirements for production orders or for stock, …

… you can use the MRP material requirement calculation method. Demand is calculated on the basis of customer orders, planned production orders, inventory levels and sales and purchase forecasts. As a result, the user receives material recommendations that take into account the current inventory, purchase and production orders.

MRP allows you to automatically generate purchase recommendations (internal demand), purchase orders with the possibility of consolidation to a selected vendor or production orders with the possibility of manual editing.

Comprehensive planning and implementation of external production (cooperation) and parts delivery.

Flexible reports and charts provide the necessary transparency to get the right tasks right at the right time.

With MRP II, resources can also be included in the calculation.

In addition to stock levels and available sales orders or framework agreements, MRP II also allows you to take into account resources and their availability. This allows you to more accurately estimate the date of delivery of raw materials for production than in the case of the MRP method, because it takes into account the availability and workload of resources at the time of planning and for the future. This saves storage space and does not involve excessive amounts of funds. On the basis of the MRP and MRP II algorithms, it is also possible to create the main schedule of MPS production and plan the financial resources necessary for involvement in a specific time perspective.

Production reporting

Comprehensive collection of data on operations, materials, manufactured products, data on quality and waste. Production reporting gives people …

… responsible for production an insight into what is happening in the production hall at any time. Collecting production data allows you to estimate whether the assumed production plan will be achieved or not and what possible actions should be taken to make the implementation as efficient as possible.

Production reporting is the basis for the planning and scheduling process.

It takes place with the help of production terminals available in the production hall with the use of any device because the application is browser-based, which means that it can be run on any device. It is enough that the hall has access to the Internet from the WI-FI network.

Job information:

possibility to work in a factory without traditional paper documents

From the terminal level, you can report:

  • Start and stop the production operation
  • Number of good and defective pieces produced and waste
  • Failures and downtime of resources
  • Inter-operational or final quality control

The terminal also allows you to use additional functions:

  • Calling up a demand for additional raw material for an order
  • Moving the raw material from the raw material warehouse to the production warehouse
  • Addition of a production operation by the operator
  • Preview of production documentation – simple opening / reading of shared documents or photos.

All of the above functions are based on the authorization policy, which allows you to control the data that can be reported by the operator.

Production cost calculation

Production costs are an important part of any business. An important function is the ability to compare the calculations before the start of the production order, …

… during its implementation and after the completion of the order.

Each enterprise has its own model of calculating production costs. Beas allows you to create your own pre and post cost calculation models taking into account:

  • Raw materials and materials
  • Technological operations
    Fixed costs and variable costs
  • Faculty costs
  • Management costs
  • Margin on operations

The calculations can be additionally made real by using price lists or groups of discounts for customers, which will allow for realistic estimation of the planned production margins.

Product / variant configurator

The product configurator is a solution that allows for the best adjustment of the product to the customer. It allows you to assemble the expected product …

… from the available stock indexes. The configurator’s functionality leads the customer by the hand indicating possible choices or narrowing them down. Of course, the functionality may be used by the sales person serving the customer instead of the customer.

The configurator’s functionality offers several benefits to the company:

  • The customer chooses a set that is possible to produce and has been provided by designers, which guides the customer and does not force the production of very non-standard versions
  • The customer can visualize the product and on this basis decide whether it suits him or not, which eliminates the level of possible dissatisfaction
  • In the background, when selecting the next options, the production technology is created (it can be used to start a production order and the price for the customer) – this significantly reduces the customer’s waiting time for product delivery

The BEAS configurator for SAP Business One is also used for production variants.

If the customer needs a special version of the product purchased so far, it will be possible to quickly prepare it using the configurator.

Important: Building a new version of an existing product does not duplicate the index in the database again. The advantage of the solution is the ability to create multiple versions / variants of the same product without the need to duplicate it multiple times in the index database.

The configurator allows you to create multi-level decision structures with variables, formulas, rules, signs, graphics, etc.

In an inquiry or sales order, the user is guided through a user-friendly questionnaire that will begin the process of configuring, calculating and integrating products after answering. The structure of the bill of materials is based on master data, indexes, bill of materials (BOM) or technological operations. It can be used outside of production as a standalone tool while you are working on a quotation or when processing a sales order in SAP Business One.

Integrations

The integration module allows you to connect with third-party applications. These can be, for example, CAD design programs or nesting programs.

These are sample programs from which you can download a bill of materials BOM to automatically create a product tree, even multi-level.

Thanks to the integration with the nesting application, it is possible to send production orders for semi-finished products so that the nesting application plans their cut.

Return to BEAS returns the list of cut components with assigned index numbers and possible scraps. However, precise information is always provided on exactly how much waste we have and in what pieces, which allows for better planning.

Benefits

The system provides many benefits in the process of running, managing and developing an enterprise. It is a comprehensive solution for small and medium-sized companies from any industry with any scope of activity. The main benefits of SAP Business One are:

Dynamic calculation of sales prices for a new product

Shortening the response time for the customer about the possible date of product delivery

Deliveries to key customers always on time thanks to the possibility of production planning according to customer priorities

Increasing the efficiency and effective use of the company’s production capacity

Making better decisions based on the current cost analysis of production or production orders – the possibility of comparing planned to actual costs

Informing about machine faults, delays and shortages in deliveries enabling quick remedial actions

High flexibility thanks to the possibility of changing the structure of the production order during production

Possibility to manually change the production plan

Analysis of places that cause blockages in the production of the so-called “Bottlenecks”

Case study

Case study

Check also

The price of implementing a production management system

The price of purchasing and implementing the system is determined by many factors specific to the industry in which the organization operates as well as individual expectations and needs of the client. The price is also influenced by the software delivery model (local or in the cloud) and the method of settlement (subscription or one-time fee). To estimate the amount of investment in a solution tailored to your needs, the following process most often works:

SEND AN INQUIRY

Using the contact form or via chat, contact us and write what system you are interested in or what problem you want to solve.

CONTACT WITH THE CUSTOMER

In the second step, our account manager will contact you to arrange the details. Thanks to this, we will get to know your needs better and choose the right solution.

SOLUTION PRESENTATION

We present a solution configured for the needs of your company and its processes. During the presentation, we also most often specify the necessary functionalities.

INDIVIDUAL PRICING

Having full knowledge, we prepare a price offer for the purchase and implementation of the system and discuss it in detail.

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