Apex Production Management

Production management is an important function of the supply chain. Production management in today’s environment is not restricted to the management of factories. These concepts are applied to a wide range of activities and situations outside manufacturing; in services such as transportation and government. Apex provides a comprehensive solution for all production processes involved in planning, order management, execution and control in a challenging production environment. Apex supports discrete, repetitive and process manufacturing. Apex supports a number of manufacturing scenarios including make to stock, make to order and engineer to order.

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Apex production management comprises of the following modules:

  1. Bill of Material (BOM)
  2. Routing
  3. Work Center & Capacity Data
  4. Product Configurator
  5. Work Order management
  6. Master Production Schedule (MPS)
  7. Shop Floor Control

Bill of material is a complete structured single or multi level list of the components required to manufacture a product. Apex supports standard, variant, order, planning, manufacturing and common bills of material to support manufacturing of different types of products. You can define any number of alternates for a primary bill of material. Bill of material is used for production, material requirements planning, sales orders and product costing. Low level code is implemented to ensure efficient MRP runs. The system handles mass change of components resulting from engineering change orders from engineering department. Multi-level and single-level explosion and implosion of BOM provides where-used list, Indented list, Where-used finished product list.

Route specifies the sequence of operations needed for the step-by-step production of a product using a bill of material. Route contains information on work centers and necessary production resources and tools for carrying out different operations. Planned operation times form the basis for manufacturing lead-times, product costing and capacity planning. Materials, production resources and inspection characteristics can be defined for each operation. The system supports alternate routes to manufacture a product using different machines and lines. Routes are used in work orders, scheduling, capacity planning and costing. The system handles mass change and engineering change orders.

A work center is where an operation or a number of operations are carried out in a production and maintenance plant. A work center can represent a machine or a group of machines as well as a person or a group of people. A hierarchal structure of production and statistical work centers can be defined in the system and associated with respective cost centers. Capacities can be maintained for a work center or independent of it. The system enables you to define machine capacity, labor capacity, reserve capacity for rush orders, emissions and energy consumption for your work centres. These capacities can also be hierarchically accumulated. The capacity and other data defined for a work center is used for different purposes like costing, scheduling and capacity planning.

Product Configurator is used to configure the products from a number of available options. The configurator displays selected model of a product along with all options and enables you to process orders for unique product configurations based on selected options. The system supports classification of mutually exclusive options, mandatory option classes, unlimited options on options, cataloging configurations, included items, quantity ranges, and dependent operations.

Production orders trigger the manufacturing of a product in a required quantity. The production order can be generated manually or automatically from MRP. A production order contains all relevant information pertaining to a particular production run like manufacturing bill of material, route, production quantity etc. The system supports all activities involved in the processing of a production order like order release, material issue, completion confirmations and material receipt to stock. The system supports printing of shop papers like pick lists, material issue slips, routing sheets, list of production resources and tools and completion confirmation slips for operations which can be bar coded to avoid manual entry for feed back. Order release also triggers generation of purchase requisition or purchase orders for the outsourced manufacturing operations.

Shop floor control is a production control and performance measurement system. It supports production optimization through effective feed back systems. Progress on different production orders can be monitored with the system to determine the work progress against target dates and control slippages. You can run different analysis on production for different time periods.

Salient features of Apex production module are:

  • Multi-level BOM, routes, work centers
  • Support for variants and options
  • Capacity roll up
  • BOM Explosion
  • Where Used Lists
  • Mass Change / Replacement Function
  • Low-Level Codes
  • Engineering change management functions
  • History maintenance
  • Change documents
  • Create and track work orders easily
  • Automated purchase requisition generation from work order

The production management is fully integrated with materials management, financials, sales & distribution, and human resource management systems.
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