Epicor Production Management

Real-time Manufacturing Kanbanthe part will be managed, manufacturers can more easily migrateto lean, while synchronizing MRP and Kanban execution.Eliminate work orders and reduce on-hand inventories as partsare electronically triggered for replenishment as needed withreal-time manufacturing Kanbans. Instead of planning for eachorder that is processed, parts are pulled through production asinventory or cell stocking levels fall below minimums. The cell isvisually queued to produce based on the Kanban quantity for thepart at its warehouse, bin or cell location.Manufacturing Execution SystemThe Manufacturing Execution System is an easy-to-use,online system for the plant floor that allows plant-basedtransactions real-time visibility throughout the Epicor solution.This easy to use interface is developed for end users and offersoptions of deployment that include touchscreen monitors aswell as bar coded enablement to simplify data entry whilereducing mistakes.Manufacturing Flow KanbanView future demand to dynamically calculate futurereplenishment Kanbans with the manufacturing flow Kanban.This gives downstream cells and suppliers visibility of futuredemand (although the actual Kanban events may differ duringexecution). As Kanbans are acted on, the downstream demandrequirement is dynamically updated. All cells and suppliers haveup-to-date visibility of future demand.Epicor MES provides accurate labor reporting, a vital concernin job costing and job status. Online transaction tracking givesmanagement a current picture of what is occurring on the plantfloor by employee and job.Integration with Epicor Job Management, Scheduling, QualityAssurance, and Advanced Material Management eliminates dualentry and provides online, real-time views of the latest plantfloor scheduling priorities. In addition, integrated documentmanagement allows plant floor access to needed documentationincluding product drawings, process documents—evenmultimedia videos of difficult to explain processes.Real-time Stock Replenishment KanbanMove inventory as it is needed in a particular manufacturing cell,shipping area or customer consignment location with the realtime stock replenishment Kanban using automatic triggering ofstocked inventory.Real-time Purchase KanbanUse the real-time purchase Kanban to replenish directly fromthe supplier and notify purchasing that a stock replenishment isrequired. Automatically send an e-mail to the supplier requestingadditional inventory against an open purchase contract.Inventory can be received to the main stores, or directly to theproduction floor. Real-time purchase Kanban automates thereplenishment of material from vendors and provides for visibilityof current supply requests.Automated Material FlowAuthorize supplying cells to make a predefined quantity of anitem being “pulled“ by using operations.Measurement of Production Activity Against LeanPerformance MetricsUse the Production Activity function to capture production dataautomatically through manufacturing center transactions. Thedata you capture through this process can then be analyzed asneeded against any lean performance metrics you define.Automatically collect and report the status of jobs on the plant floor inreal time.Lean MetricsIndicate lean metrics by period, day, week, resource group,even free form parameters such as seasonal. Use the ProductionActivity tracker to dynamically evaluate the production activity foreach resource group against the lean performance metrics youhave established for your manufacturing processes.Flexible Data Entry TechnologySupport for Hybrid Approaches to LeanDocument ManagementUse touchscreen, mouse, bar code, or keyboard interface toupdate labor information from the plant floor. Eliminate dataentry mistakes and increase transaction speed by simply scanninga bar code tag to complete a transaction.Employ a phased approach to implementing lean practices fortracking material, MRP and Kanban in a mixed environment. Byoffering manufacturers the choice, at the part location level, howIncorporate employee pictures, product and process documents,including product CAD/CAM drawings or even video instructionson how to perform a process.4

Work QueueMaterial HandlingProvide employees with prioritized work schedules and makeinformation directly available to the plant floor. Optimizedfor use on the plant floor with the ability to select multipleoperations for work at the same time, full sheet views, viewsspecific to current, available, or expected work, ability totarget work based on TAKT, pieces, hours, and setup groupdesignations, and advanced search capabilities.In combination with Advanced Material Management, maximizeresponsiveness of material handlers with material move queuesand give operators the ability to request in process WIP movesof product from one location to another, maximizing control ofin process products while reducing delays. Additionally, moveWIP products into inventory storage locations or stage WIP atthe next resource based on available space and time. Quicklyand accurately identify WIP and inventory containers with systemgenerated bar codes.Multiple LanguagesDisplay the Manufacturing Execution System screens in theemployee’s primary language.Advanced MESDistributed HoursEpicor Mattec Manufacturing System (MES) extends your Epicorsystem to provide automatic production monitoring and processmonitoring, empowering manufacturers with production dataand the ability to eliminate inaccurate and time-consumingmanual data collection; so operators can stop measuring andmonitoring, and focus on making quality products.Automatically split labor hours across multiple jobs being workedon simultaneously by an employee. Likewise, split resource ormachine hours when two or more employees work on thesame resource.Quality ReportingCapture rework and scrap reason codes, along withmiscellaneous employee comments from the plant floor. Use theQuality Assurance options to report setup inspection, first article,piece counts, and more.If you’re ready to become more competitive with Lean and SixSigma initiatives, advanced MES delivers the data, analysis androot-cause information automatically. You can achieve informedlights out manufacturing, and get the powerful metrics you needto improve performance—Overall Equipment Effectiveness (OEE),run rates, scrap, yield, energy consumption, material consumption,and much more. Accurate machine-related data, along withoperator depth and dimension helps you pinpoint critical issues,reduce waste, and improve quality and customer service.Shop WarningsShop warnings appear in various locations throughout thesystem when certain conditions exist or certain events occur.They are intended to keep supervisors informed of a job’s statusor an employee’s performance. Digital and analog machine signals directly from sensors orPLCs, or via OPC-compliant PLCsGrace Periods/Multiple ShiftsManage clock-in and clock-out periods with adjustmentsmade for user-defined grace periods. Accommodate split andstaggered shifts. Role-based displays and dashboards for operations, plant, andmanagementDeploy Your WayTrackers in the PlantEpicor makes it easy to get there—advanced MES runs oncurrent Microsoft Windows Server with SQL Server. EpicorAdvanced MES has the industry know how to connect to or geta signal from any kind of machine, no matter how timeworn ormodern, and the system uses machine interface units (MIUs),open connectivity protocol (OPC), programmable logic control(PLC), and personal computer (PC) interfaces.Users can access online trackers on the plant floor from withinMES. From Job Tracker, Order Tracker, Customer Tracker,Shipment Tracker, and more are available based on login andsecure access.Shop TrackerAccess who’s here, who’s not here, current work center activity,as well as user-defined alert conditions from theplant floor.UsabilityThe advanced MES collects production data automatically—nomore manual data collection to worry about. Operators usetouch-screen technology to add depth and dimension to theautomatic production data, so you get a clear picture of thewhat, why and when of downtime, cycle time, quality, and scrap.Operator help calls with automatic routing and notificationsempower employees to respond quickly, improving productivity.Shipping and ReceivingIn combination with Advanced Material Management, maximizeresponsiveness in the warehouse with Shipping and Receivingfunctions from within MES.Inventory ManagementIn combination with Advanced Material Management, maximizeresponsiveness in the warehouse with Inventory functions suchas adjustment, material issues, physical inventory counts fromwithin MES.5

Plant NotificationWhat-if analysis combines with built-in machine capacityplanning and labor and material forecasting for better planning.Advanced MES supports Kanban scheduling.The system also has real-time automated alerts, notifications,escalation and other communications, so the people who need toknow are in the know when it matters the most—immediately,so they can take action to correct a problem, or improveperformance on-the-spot. Automated alerts include machineconditions, cycle, process variations, efficiency, and scrap.Energy MonitoringTackle power consumption and the cost of energy with EnergyMonitoring. Epicor helps you analyze load patterns, productionrequirements, and resource energy demands, giving you thepower to reduce peak demand and capture energy savings.With Epicor, you can quickly and easily capture and analyzeenergy performance indicators (EPIs) to reduce consumptionand cut costs.Office, Mobile, and GlobalTake the power of Advanced MES with you on a Web-enabledmobile device or tablet with browser-based dashboards,information, and analysis. Plus, it doesn’t matter if youhave a single operation, or a distributed network of plantsinternationally, the system is currently available in more than 10languages, and suitable for language customization. Monitor and analyze energy consumption by machine, job,shift, product Real-time scorecardsVisibility, Reporting, and Analysis Understand maintenance and quality in context of energyconsumptionFrom the “top floor to the shop floor”, it’s important to knowthe score, every minute of every shift, every day of the year.Epicor scoreboards and displays empower front-line professionalsto take action and make improvements instantly. Maintenance,quality, and other operations stakeholders have facts in-handto support recommendations, and management has what theyneed to understand tradeoffs from every angle. Evaluate idle vs. shutdown-restart tradeoffs Analyze price accuracy with direct energy required to produceany item Monitor energy by asset, job leveling, and loading Plant floor viewer with real-time machine stateand job monitoring Consistent, automated, OEE and other efficiency metrics Production metrics from machine to enterprise level Downtime and scrap analysis Operator labor and productivity Performance versus schedule, labor forecast, tool conflict, joband part historyReduce operating energy cost with energy monitoring.Quality ManagementEpicor extends accountability to the machine performing the work,and give operators time to respond before an event affects qualityand performance. And, Epicor makes the job even easier with easyto-digest quality trend information, to engage your production teamand help them become proactive. Automatic part qualification/rejectionEmpower production managers with equipment driven analytics. Part and machine process data for traceability purposesSchedule Optimization Statistical quality control (SQC) and statistical processcontrol (SPC)Advanced MES helps the plant change instantly based on newrequirements with a click-and-drag production schedule. Or, youcan watch the schedule update and adjust automatically basedon actual machine speeds, production counts, equipment status,conditions, or job specifications. The system makes it easy toplan by showing resource availability based on machine/part/toolcompatibility, and optimal plans based on prior part performance.6

Machine Maintenancecertainly don’t have enough data points to become proactive.Epicor Informance EMI lets you create a closed-loop process toeliminate production loss–downtime that can be used for morecapacity. We’ll help you use big data collected directly fromequipment to assess and prioritize problems, and even determineif losses are random or chronic, so you can push them throughthe right process.Epicor pays close attention, making it easy to stay on trackwith maintenance schedules, equipment performance, energyconsumption, and statistical quality. Preventive maintenancecapabilities help operators stay on track too, with informationthey need to affect quality or performance. Machine and tool preventive maintenance (PM) Cycle or run hour PMQuality Assurance Automated alarms and notices for PMExtending your solution with Quality Assurance ensures thatcomplete visibility of quality operations including visibility ofitems in the quality process. Accurate costing demands thatproducts moved through quality accurately reflect their value andare removed from appropriate WIP. Additionally, this moduleincludes processes for supplier returns with links to AccountsPayable for automated debit processing; closing the loop ontraceability of products in and out of quality within the plant.Enterprise Manufacturing IntelligenceTrack, measure and analyze downtime and plant performance—instantly and over time—to eliminate random and chroniclosses—on the front line, throughout the plant, and across theproduction network. Automated data collection direct from yourmachines is the gold standard in performance improvement,and Epicor exceeds that standard with analysis, reporting andplanning to help you achieve your goals. You decide whichmetrics will help you have the greatest impact on availability,performance and quality, while Epicor helps you collect andunderstand the root causes of loss.Tie together all quality functions, whether it’s scrapping endparts, rejecting raw materials or tracking first article inspections.Inspectors have queues of items to inspect with full dispositionand corrective action follow-up. Plant floor employees can flagparts as nonconformant, which moves them into an inspectionqueue. Parts that fail inspection may be flagged for review by amaterial review board.Monitor and Analyze PerformanceAccurate data, instantly and on-the-fly, not minutes, hours,or shifts later, helps you find more capacity. When you makemore without more assets, you improve profitability. EpicorInformance Enterprise Manufacturing Intelligence (EMI) collectsdata directly from equipment and operators on the shop floorin real time, eliminating inaccurate and time-consuming manualdata collection. With information in your hands “right now” youcan become proactive, so you anticipate and solve productionproblems immediately. You and the entire operations andproduction teams can work collaboratively to reduce downtime,and optimize equipment, capital, and worker resources, anddrive performance gains. Over 1000 analysis choices available out-of-the-box One-click drill-down visual root-cause indicators Accurate, visual performance trend analysis Automated data collection to eliminate time-consuming, errorprone manual interventionRecord and track quality data to fulfill customer requirements andpromote continuous improvement. Role-based metrics, displays and dashboards for operations,plant, and managementSocial Quality Metrics in standard and financial context, based on producttypes, size, brand (and many others)Collaborating the right resources to improve quality often meansredundant communication and events. Using social quality groupsenables quality events to be resolved faster and long term qualityimproves as a result of this collaboration. Single plant and multi-site performance analysisLeverage Big Data in ManufacturingQuality no longer needs to be an isolated department, incollaboration with engineering, production, and sourcing, qualitynaturally improves. Cost of quality is also reduced dramatically.It’s all about the little details, and responding at the right time.Operators don’t have time to gather, organize, and analyzeenough data to respond to problems, so they react. They7

Mobile Qualityof Quality (COQ), or Certificates of Compliance. To help manage thisdocumentation, Epicor includes the ability to check for Certificates ofCompliance at receiving of materials from suppliers, receiving of inprocess parts from outside operation suppliers, and before shippingproducts to customers.Access to information at the point of checking and recording qualityevents reduces the inaccuracies and improves efficiency of qualityprofessionals. Whether recording inspection results or respondingwith root cause analysis to a corrective action, information aboutquality that is inclusive and tied throughout the business improvesoverall business quality.Enhanced Quality AssuranceInspection WorkbenchTraceability and audit of quality data drives businesses to develop“systems”, many times paper based, to support the collectionand use of quality testing data. Enhanced Quality Assuranceis designed to extend base Quality Assurance with support forthe management of controlled test plans and the results forproducts, groups of products, processes, and other testing. Itoffers the ability to define testing elements or attributes as wellas lists of attributes to test which can be used to measure againsttesting results for pass/fail decision criteria. It includes the dataused for Statistical Process Control (SPC) and is easily accessedto build SPC analysis. In essence, Enhance Quality Assurancegathers the data and makes it available to ensure that your nextaudit goes smoothly.Monitor WIP, review all inspections in priority and automaticallytake action on those requirements from the inspection workbench.Inspectors move passed parts back to jobs and failed parts intodiscrepant material report (DMR) processing, or they simplyscrap them.Nonconformant RecordsCreate a nonconformant record (NCR) for all nonconformant parts.From a job, shop floor employees automatically create an NCR whenthey scrap an end part or raw material. Inventory personnel createan NCR when they scrap parts from inventory.Non-Netting BinsUse non-nettable bins to keep parts undergoing inspection oron-hand quantities.Enhanced Quality Assurance is a fully embedded component ofthe application and is configured to use serial and lot trackingfor each sample, storing this data within the results database.Document management, a cornerstone function of the systemis linked to inspections plans and individual specification lists andenables access to key documents during results collection. Finally,this module takes advantage of robust configuration tools toenable results entry forms to be configured to match uniquebusiness test plans layouts. Familiarity of layout of test plans andresults entry ultimately reduces the training effort to bring thesystem online.Discrepant Material Report ProcessingAfter failing inspection, create a DMR to provide the MRB with anonline queue of parts that need to be dispositioned.Corrective ActionCreate and track all preventive and corrective actions online. Withdue dates, audit sign-offs and unlimited comments, correctiveactions provide for follow-up of quality issues.Material Review BoardIn addition to production and receiving inspections, when used incollaboration with Epicor Maintenance Management, calibrationtest plans are available for resources, equipment, and assets.This ensures not only the accuracy of quality data collected fromthese devices, but it can also be used to validate any equipmentagainst business standards with auditable results.Disposition parts by an MRB after failing inspection. Onlinedocumentation provides an audit trail of MRB actions.Cost of QualityGenerate cost of quality reports to identify how much qualityproblems are costing you, whether parts are scrapped frominventory, a job or receipt inspection.For businesses looking to not only perform receiving inspections,but attach logic to the frequency of inspection, Enhanced QualityAssurance offers skip lot rules that define the frequency ofinspection for each primary supplier at the part level.Packing SlipsPrint a customizable packing slip for all parts returned.Debit MemosQuality solutions today include not only tracking of quality events(such as inspections and non conformances) as they happen;they also include a proactive approach to quality by ensuring thatthe employees performing job functions are properly trained (ISOstandards). Epicor Enhanced Quality includes a robust employeetraining feature set that supports the management of trainingcourses and course schedules for certification programs andonsite/offsite events. Supporting your business objectives forcross training your workforce, employee training functions trackemployee attendance alongside performance and offer flexibleemployee training request features to enable employees to selfrequest training or have training assigned to them.Create a debit memo in DMR processing and it is automatically tiedto accounts payable.Audit TrailsView inventory transaction detail occurring in inspection and DMRprocessing with the material transaction detail report.Certificate of ComplianceBusinesses are increasingly requiri

Human Capital Management Product Data Management Project Management Financial Management Production Management Planning and Scheduling Job Management . Epicor Job Management, users can more easily identify wasted processes and continuous improvement opportunities on the