Alpha MRP Benefits

100% Web Based Alpha MRP saves manufacturers time and money. Read on about MRP benefits...

To ensure the production and delivery of high-quality finished goods, manufacturers have to be able to effectively produce, manage and track goods, information and resources across the enterprise and supply chain while adhering to increasingly stringent quality standards. Success starts with effective management of products and the manufacturing process.

While most generalized MRP systems fall short of addressing critical needs of manufacturers that make and package products through recipe- and formula-based processes, Alpha MRP is designed to help manufacturers worldwide to succeed in these endeavors.

Manufacturing Resource Planning (MRP) and management is a highly integrated and complex solution controlling your entire manufacturing management activity.

The Core Functionalities of MRP consists of:

• Engineering Management
• Demand Management
• Sales Order Management
• Master Production Planning and Scheduling
• Production Order Release
• Shop Floor Control with Lot Traveler and Machine Loading Sheets
• Material Requirement Planning
• Material Stores and Finished Goods Stores Management
• Shipment Management
• Purchase Management
• Quality Control and Plant and Machinery Maintenance Management modules etc.

Manufacturing Resource Planning - MRP Benefits

Because Alpha MRP is designed with quality control (QC) as an integral part of processes, quality can be planned and managed just like any other process. This means you'll have precise control over all materials and products (co-products, by-products and end-products).

Throughout the entire processes, from formulation to production and distribution, you can be more diligent in batch scaling, date code tracking and lot tracing.

Additionally, with MRP, you can define and measure customer quality specifications at critical steps in the process. You can maintain the quality of your processes and products within strict tolerances to minimize delays and associated costs, and ultimately satisfy the expectations of your customers.

Shelf-life planning capabilities enable you to optimize production scheduling while inventory control software helps better manage the expiration of materials and finished goods and maximize the shelf-life of shipped products.

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Multiple Production Types Support

• E.g. Process, Repetitive, Make-to-order, Make-to-stock etc.

Integrated Planning

• Tight Integration with other departments creates efficient planning

Fully and Partially Automated Lines Integration

• To process control systems, Lot Transactions and PI Sheets

Strict Documentation Requirements

• As per TQM, APICS manufacturing standards required.

Manufacturing Resource Planning (MRP) Workflow
(Click on image to enlarge)

Alpha MRP - Manufacturing Resource Planning System Functions:

Side Bar:

• Top Management often asks: During the past years how often we failed to keep delivery dates?
• Production Manager often asks: What is the trend in quality over last 10 batches?
• Line Operator often asks: What stage each batch has reached? When will a particular batch come to me?

MRP benefits - Process Engineer:

• Enter Process Master and Manufacturing Process: A process master and its object contain all the information required to describe a production process. The most important routing objects are operations, sub-operations, sequences of operations, material components and inspection characteristics.
• Define Route Sheet: To define sequence in which above operations to be performed in production process should be specified.
• Sequence of Manufacturing Operations
• Machines used for each operation.
• Inputs, outputs, yield time and manpower for each operation.
• Move points, finished goods receipt points, back flush points, QC Points for each operation. The move point flag is like milestone. If this flag is set on, that means system will prompt the operator to key in Yield Quantity and operation times and move operation.
• Reject codes are entered in separate Rejection/Scrap Management screen. This milestone will disallow confirmation of subsequent operations prior to confirmation of the milestone. In this manner, key manufacturing steps or quality operations can be marked as required, so they are not intentionally or unintentionally bypassed.
• Finish goods receive point definition can specify that an automatic goods receipt can only be posted once per production order. Consumption of raw materials automatically based on a production confirmation is called back flushing. If a QC Point flag is set on, the system will ask user to key-in Quality Control information for that lot. Move Point flag is also set on when QC Point flag is set on.
• Standard Operating Procedures or Process Instruction Sheets: To define process parameters, data requests, data calculation formulas.
• Define Process Items: To define material name used for operations in the production process is specified.
• Process Info System: To get info of the process in the manufacturing of a product.

More on Manufacturing Resource Planning ...

MRP benefits - Project Engineer:

• Define Projects as Service - Construction or Discrete Manufacturing
• Define project in the project master giving details like the name of the project, plan date, units of project
• Define Project Teams: To define the team formation date, name, description, the role of the team, role assigned to employee or any user of Alpha MRP as member of above mentioned team.
• Enter Linked Activities: To enter inter-related activities in a project as successful implementation of the project involve planning, co-ordination and control of the activities.
• PERT/CPM Charts, Slack, Critical Path: In critical path method it is assumed that activity durations are deterministic or are known with certainty. The method will compute the earliest possible start time and latest possible start time for each activity. In addition it will identify the critical activities.
• Project Costing Estimated versus Actual
  Project Info system

MRP benefits - Material Engineer:

• Enter Item Types: To define item types - direct raw materials, finished products, semi-finished products, indirect raw materials.
• Enter Product Groups: To define product group to classify the items.
• Enter Item Master as Products, Materials, Services or Projects etc.: To define item name, item type, whether the product is finished good to be sold or stock.
• Define Bill of Materials: To define the materials to be used in the production of a product along with the process name each material is to undergo to reach final product stage.

MRP benefits - Shop Floor Manager:

• Edit Production Order: To edit the production order for changes in schedules of the operation to be carried for the product to be manufactured.
• Lots Traveler: Same as route sheet/job card.
• Lots Transactions: Movement of the lots/jobs on the shop floor
• Move Lots: Move lots from one process to another
• X Move Lots
• Merge Lots
• Split Lots
• Terminate Lots
• X Terminate Lots
• Lots/Batch Reports
• Stuck Lots
• WIP Report
• Cycle Counting
• Work Calendars for Work Centers
• Generate Machinery Load Schedule
• Generate Manpower Load Schedule
• Automatic stores MR requisition for Kit: Automatic issue of materials from stores as per production order generated.

MRP benefits - MPS / MRP Planner:

• Run MRP Server
• Create Master Production Schedule based on Distribution
• Plan, Stock and Work-in-Process
• Project gross raw materials requirements
• Create Lots
• Production order if plan feasible with respect to capacity, material manpower
• Revise Production Schedule on shortages
• Capacity Utilization
• Manpower Utilization
• Create Direct Material Requirement Plan with respect to Production Plan by carrying out BOM explosion
• Create In-Direct Material Requirement Plan based on ROP: Re-order point planning for indirect raw materials
• Create Purchase Orders for shortages found in MRP or ROP Plans
• Planner Info system

Info on Manufacturing Resource Planning continues ...

MRP benefits - Maintenance Engineer:

• Enter Maintenance Plan
• Track Maintenance Schedule
• Maintenance Info System

MRP benefits - Quality Manager:

• Define comprehensive Quality Control specs for each item by entering Reject Codes
• Incoming Materials Quality Control
• Approve or Reject Goods Receive Note (GRN) and create DR.
• Line Quality Assurance (QA) in Shop Floor
• Enter Line Rejection
• Outgoing Goods QC
• Quality Certification
• Track Lot Rejection by Operation Work centers
• Track Material Rejection by Vendors
• Generate Intimations for Q.C. for testing of intermediates and finished goods
• Quality Info system

MRP benefits - Shop Floor Operator:

• Move Lots

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