RFID/ Barcode Solution

We have designed and implemented a complete Barcode solution for one of our main clients in the textile industy.

The main features of this solution are:

a. Operator yield analysis
b. Rejects or reworks per operator
c. Raw Material to finished product batch tracking
d. Automated order confirmation
e. Supervisor efficiency analysis.

It is an SAP Netweaver based solution that supports the following features using the wireless barcode scanners

a. Quality Inspection using barcode and create rejection barcode labels for reject material
b. Goods movement reducing human errors to maximum possible extent
c. Capture operator time spent at each activity center or work center
d. Capture operator yield at each work center
e. Track rework material operator wise using barcode label
f. Confirm the production order based on operator yield

Using the solution, the end user can

a. Print barcodes while doing goods receipt against a purchase order
b. Keep track of the operator history from raw material to finished product
c. Report on operator yield per activity per material type per month
d. Report on supervisor efficiency per activity

The solution has been designed in such a way that it that can easily be upgraded to an RFID based system.

The solution is built utilizing the services provided by SAP. It integrates the SAP modules of SD, MM, FI, PP, QM and Project systems in order to provide a complete integrated reliable tool.

Every single production process will be executed/ tracked as a project. The project plan will be based on a template. In a make to order scenario, this is linked to a sale order line item with flexibility to modify the sub processes during a project execution. Update of sub processes completion is automated giving a real time snapshot of the execution progress to the top management. The inbuilt alert framework ensures that the management is updated for any critical delays/ processes.

All the relevant information required for decision making will be available to the concerned stakeholders. An easy to use and intuitive UI reduces the time taken for rollout to production.

The current solution has been designed to suit a Make to Order scenario. This can be configured for a Make to Stock scenario. This can also be adapted to any generic process.

Purchase Order Control

In order to maintain the sales order profitability leading to overall profitability of the organization, there is a need to control the cost of production that depends mostly on the following parameters

a. Cost of procurement of components
b. Cost of production
c. Overheads

This is possible using the concept of ‘Cost Sheet’ where the maximum cost of purchasing components can be set by the management using our application. This in turn controls the price in the purchase order. Any upward deviations in the price need an approval from the management.

Sales Order Status

At any point in time, for a given sales order, the management needs an answer for the following questions

a. What are the items in the sales order?
b. Which items in a BOM are manufactured via a production order and which are procured using a Purchase Order?
c. What is the execution status of a sales order?
d. What is the overall status of a sales order?

Our solution is the answer to all these questions and many more. It provides a single user interface where any user can get the complete status of any sales order from creation to completion including all the related process like purchasing, production, delivery and others. The solution is also available as in BW for better analysis and understanding.

Opportunity to Order

The main features of this solution are

a. Manage all opportunities and track them till order realization
b. Handle budgeting and approvals for sample creation
c. Workflow integration via MS Outlook to ease user interaction

The Opportunity to Order solution can be used to keep track of all opportunities coming into the organization. The entire lifecycle of the opportunity can be tracked till the creation of a sales order. This is fully integrated with our other solutions like Purchase Order Control and Process execution & control systems. This ensures proper cost control during sample creation and also helps track an opportunity all the way to delivery and payment. A strong reporting system integration (including BW) helps the top management improve the opportunity handling process.

EXIM Solution
(Development in progress)

The main features of the solution are

a. Covers all statutory requirements for EXIM companies in India
b. Covers all relevant EXIM processes within SAP
c. External & Internal documentation stored within your system
d. Relevant documentation at the tips of your fingers

EXIM solution, run on SAP Netweaver, is customized to handle documentation and statutory requirements of Export and Import business houses in India. With EXIM all the pre-shipment documents and post-shipment documents can be generated and maintained easily. Also documents which are obtained from the government in certain scenarios can be stored effectively in the SAP ERP system for future references. At the same time the EXIM solution is flexible to adapt any of the business processes to meet new legal requirements within a short period of time.

The EXIM solution provides checklists, documentation printouts, alerts, cross reference to SAP standard business processes. This makes the complex statutory process easier to handle.