Royal 4 ERP: Manufacturing

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Royal 4's Manufacturing & Planning Modules

The R4 manufacturing modules were designed primarily to handle the discrete manufacturer's requirements with special emphasis on Job Shop, Make-to-Order, Engineer-to-Order, and Make-to-Stock environments. However, R4 production modules have also provide support to companies running repetitive manufacturing and process manufacturing environments. It offers extensive functionality across the breadth of manufacturing to help you provide the highest quality products while maintaining profitability through efficient and low cost production.

R4 easily responds to your business requirements with modules necessary to run your operations. At the heart of the manufacturing operations is a Manufacturing Design (BOM) module and a Production Activity Planning (PAC) module. The Product Structure serves as a central repository for all assembly and component relationships and the process (routing) identifies all discrete manufacturing steps.

The R4 planning modules enables a company to plan for long term production needs (MPS) that covers resource requirements (CRP) and short term material requirements (MRP). Master Production Scheduling (MPS) deals with first and second level products; Material Requirements Planning (MRP) provides production and procurement departments with the information needed to maintain a smooth flow of materials and supplies.

Manufacturing Design (Bill of Materials)

This is the engineering module of R4 and provides for the entry and maintenance of the Bill of Materials, the manufacturing process for finished goods and components and calculates the product costs. Full integration with all the appropriate modules helps insure complete product integrity throughout the system. Define the elements that make up the multi-level bill of material for an item with product structure maintenance.

The BM module supports unlimited levels of components and processes. Standard operations include inside and outside processing. Work centers are defined in terms of capacity, employees, machines, utilization, efficiency, direct labor and overhead costs. Cost rollup programs can be executed for individual items or all items, it enables analysis of resulting costs of materials, labor, machinery, outside processes and overhead on a "Costed Bill of Materials Report".

Production Activity Control

Working with inventory management and manufacturing design, the production activity control module (PAC) tracks manufacturing activities from issuance of work orders to completion of jobs. It encompasses shop floor control, job costing, and labor performance functions. Work orders could be manually launched, triggered by make to order environments, or created by MRP, DRP or MPS planned orders.

Work orders could be created using the standards established in the manufacturing design module and print them to provide accurate documentation on the shop floor while simplifying paper flow. Track costs by entering time and materials on a job by job basis; variance from standards are measured for material rate and efficiency, labor rate and efficiency and applied burden. The PAC module can help a company as a result of:

  • Improved productivity.
  • Improved quality.
  • Improved customer satisfaction.
  • Improved inventory control
  • Improved costing

Material Requirements Planning (MRP)

R4's MRP module follows guidelines set forth by APICS and is a complete MRP system in which closed loop MRP technology drives the R4 material requirements planning module. Information from sales orders and sales forecasts, interact with the IM, PO and PAC modules, to produce a time-phased material requirements plan. These time-phased plans, use infinite backward scheduling logic to arrive at the requirement dates for unlimited planning horizons.

MRP computes the requirements for both the component sub-assemblies, as well as the finished assemblies. Used properly, MRP can enable a company to achieve the following:

  • Improved customer service.
  • Reduced inventory levels.
  • Increased productivity while reducing costs.
  • Improved management.

Master Production Scheduling

The R4 master production scheduling module (MPS) provides time-phased demand and production planning information and helps you establish the vital strategic link between corporate planning and actual production capacity. By tracking actual production against forecast, it allows you to develop realistic "on-hand" and "available-to-promise" quantities and optimize work order release and PO timing quantities. User defined planning horizons, time fences, time buckets, and sensitivity filters allows presentation of information in a more meaningful way.

The MPS module is used for projecting long-term resource requirements, calculating loads at work centers, tests the feasibility of the production plan and determines future utilization of work centers. MPS works with single and two level BOM's and integrates with MRP for detail materials planning. The MPS module helps a company to:

  • Increase production efficiency.
  • Match corporate strategy with production and marketing.

Capacity Management

To make maximum use of manufacturing production facilities, available capacities of each and every resource must be known and planned. The R4 capacity management module allows you to define and maintain resource capacities in time driven blocks. Resource bills must be defined and maintained for an item or a group of items. Production planners can generate rough-cut capacity plans, resource requirement plans and net change capacity plans.

R4's CRP analyzes data from shop orders, planned orders, and actual orders to forecast how these orders will impact shop floor capacity by work centers. It helps to first identify bottlenecks and then how to eliminate them by determining the work load for each work station. It allows you to run what if scenarios until you find the optimum plan. This is a serious tool designed to help production operations run as efficiently as possible.